Electronic Controlled Lpg/Gasoline Fuel System: GM 3.0L and 4.3L Epa Compliant Engines

ELECTRONIC
CONTROLLED
LPG/GASOLINE FUEL
SYSTEM
GM 3.0L AND 4.3L EPA COMPLIANT
ENGINES
H2.00-3.20XM (H40-65XM) [H177];
S2.00-3.20XM (S40-65XM) [D187];
H3.50-5.50XM (H70-120XM) [L005];
H6.00-7.00XL (H135-155XL,
H135-155XL 2) [G006];
S6.00-7.00XL (S135-155XL,
S155XLS, S135-155XL 2) [C024];
S3.50-5.50XM (S70-120XM) [F004]
PART NO. 1559540 900 SRM 1088

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Electronic Controlled LPG/Gasoline Fuel System Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
Fuel System Warnings and Cautions ............................................................................................................. 1
Glossary ................................................................................................................................................................ 2
Description and Operation of LPG Fuel System ................................................................................................ 6
Propane Fuel System....................................................................................................................................... 6
LPG Fuel Tank................................................................................................................................................. 8
Service Line...................................................................................................................................................... 8
Fuel Filter ........................................................................................................................................................ 8
Low Pressure Lock-Off (LPL).......................................................................................................................... 9
Low Pressure Regulator (LPR) ....................................................................................................................... 9
Air Fuel Mixer ................................................................................................................................................. 9
Throttle Control Device ................................................................................................................................. 10
Drive By Cable........................................................................................................................................... 10
Three-Way Catalytic (TWC) Muffler ............................................................................................................ 11
Electronic Control Module (ECM) ................................................................................................................ 11
Heated Exhaust Gas Oxygen (HEGO) Sensor ............................................................................................. 14
Description and Operation of Gasoline Fuel System ....................................................................................... 14
Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine Only ................................................... 14
Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only ................................................................ 16
Gasoline Fuel Storage Tank.......................................................................................................................... 16
Gasoline Fuel Pump ...................................................................................................................................... 16
Fuel Filter ...................................................................................................................................................... 16
Fuel Pressure Regulator, 3.0L Only ............................................................................................................. 18
Fuel Rail and Pressure Regulator, 4.3L Only .............................................................................................. 18
Fuel Injector................................................................................................................................................... 18
Throttle Control Device ................................................................................................................................. 18
Drive By Cable........................................................................................................................................... 18
Three-Way Catalytic Muffler ........................................................................................................................ 19
Electronic Control Module (ECM) ................................................................................................................ 20
Heated Exhaust Gas Oxygen (HEGO) Sensor ............................................................................................. 21
LPG Fuel System Repair ................................................................................................................................... 22
Propane Fuel System Pressure Relief .......................................................................................................... 22
Propane Fuel System Leak Test ................................................................................................................... 22
Propane Fuel Filter Replacement................................................................................................................. 22
Remove....................................................................................................................................................... 22
Install ......................................................................................................................................................... 23
Low Pressure Lock-Off (LPL) Replacement ................................................................................................. 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 23
Pressure Trim Valve (PTV) Replacement ..................................................................................................... 25
Remove....................................................................................................................................................... 25
Install ......................................................................................................................................................... 25
Low Pressure Regulator ................................................................................................................................ 25
Remove....................................................................................................................................................... 25
Install ......................................................................................................................................................... 25
Fuel Trim Valve (FTV) Solenoid Replacement............................................................................................. 26
Remove....................................................................................................................................................... 26
Install ......................................................................................................................................................... 26
Temperature Manifold Absolute Pressure (TMAP) ..................................................................................... 29
Remove....................................................................................................................................................... 29
Install ......................................................................................................................................................... 29
©2006 HYSTER COMPANY i

Table of Contents Electronic Controlled LPG/Gasoline Fuel System
TABLE OF CONTENTS (Continued)

Throttle Body Replacement .......................................................................................................................... 29
Remove....................................................................................................................................................... 29
Install ......................................................................................................................................................... 30
Mixer Replacement........................................................................................................................................ 30
Remove....................................................................................................................................................... 30
Install ......................................................................................................................................................... 30
Coolant Hose Replacement ........................................................................................................................... 30
Remove....................................................................................................................................................... 30
Install ......................................................................................................................................................... 31
Vapor Hose Replacement............................................................................................................................... 31
Remove....................................................................................................................................................... 31
Install ......................................................................................................................................................... 31
Balance Line Hose Replacement .................................................................................................................. 31
Remove....................................................................................................................................................... 31
Install ......................................................................................................................................................... 31
PTV Hose Replacement ................................................................................................................................. 31
Remove....................................................................................................................................................... 31
Install ......................................................................................................................................................... 31
FTV Hose Replacement ................................................................................................................................. 32
Remove....................................................................................................................................................... 32
Install ......................................................................................................................................................... 32
Throttle Position Sensor (TPS) Replacement............................................................................................... 32
Foot Pedal Position (FPP) Sensor Replacement .......................................................................................... 34
Electronic Control Module (ECM) Replacement .......................................................................................... 37
Remove....................................................................................................................................................... 37
Install ......................................................................................................................................................... 37
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement....................................................................... 38
Remove....................................................................................................................................................... 38
Install ......................................................................................................................................................... 38
Three-Way Catalytic Muffler (TWC) Replacement...................................................................................... 38
Remove....................................................................................................................................................... 38
Install ......................................................................................................................................................... 38
Restricted Exhaust System Diagnosis.......................................................................................................... 38
Exhaust System Description .................................................................................................................... 38
Tools Required ....................................................................................................................................... 38
Diagnostic Tool ...................................................................................................................................... 38
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) ......................................................................... 39
Gasoline Fuel System Repair ............................................................................................................................ 39
Gasoline MPFI and TBI Fuel System Pressure Relief ................................................................................ 39
Gasoline Fuel System Leak Test................................................................................................................... 40
Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only ............................................................... 40
Remove....................................................................................................................................................... 40
Install ......................................................................................................................................................... 40
Throttle Body Assembly Replacement, 3.0L Only ....................................................................................... 42
Remove....................................................................................................................................................... 42
Install ......................................................................................................................................................... 42
Throttle Body Assembly Replacement, 4.3L Only ....................................................................................... 42
Remove....................................................................................................................................................... 42
Install ......................................................................................................................................................... 43
Fuel Rail Replacement, Gasoline 4.3L Only ................................................................................................ 45
Remove....................................................................................................................................................... 45
ii
Electronic Controlled LPG/Gasoline Fuel System Table of Contents

Install ......................................................................................................................................................... 45
Injector Replacement, Gasoline 4.3L Only................................................................................................... 45
Remove....................................................................................................................................................... 45
Install ......................................................................................................................................................... 45
Injector Replacement, Gasoline 3.0L Only................................................................................................... 46
Remove....................................................................................................................................................... 46
Install ......................................................................................................................................................... 46
Temperature Manifold Absolute Pressure (TMAP) Replacement............................................................... 46
Remove....................................................................................................................................................... 46
Install ......................................................................................................................................................... 46
Throttle Position Sensor (TPS) Replacement............................................................................................... 46
Foot Pedal Position (FPP) Sensor Replacement .......................................................................................... 49
Electronic Control Module (ECM) Replacement .......................................................................................... 52
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 52
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement....................................................................... 52
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 53
Three-Way Catalytic Muffler (TWC) Replacement...................................................................................... 53
Remove....................................................................................................................................................... 53
Install ......................................................................................................................................................... 53
Restricted Exhaust System Diagnosis.......................................................................................................... 53
Exhaust System Description .................................................................................................................... 53
Tools Required ....................................................................................................................................... 53
Diagnostic Tool ...................................................................................................................................... 53
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) ......................................................................... 53
LPG System Diagnosis ...................................................................................................................................... 54
Fuel System Description ............................................................................................................................... 54
Diagnostic Aids .............................................................................................................................................. 55
Tools Required ........................................................................................................................................... 55
Duty Cycle Monitoring Tool ...................................................................................................................... 55
Diagnostic Tool .......................................................................................................................................... 55
Pressure Gauges........................................................................................................................................ 55
Test Description......................................................................................................................................... 55
Gasoline System Diagnosis ............................................................................................................................... 63
Fuel System Description, 3.0L Only............................................................................................................. 63
Fuel System Description, 4.3L Only............................................................................................................. 63
Diagnostic Aids .............................................................................................................................................. 64
Tools Required ........................................................................................................................................... 64
Diagnostic Tool .......................................................................................................................................... 64
Test Description......................................................................................................................................... 64
LPG Symptom Diagnosis................................................................................................................................... 71
Gasoline Symptom Diagnosis............................................................................................................................ 85
Wire Harness Repair ......................................................................................................................................... 95
On Vehicle Service Wiring Harness Repair.................................................................................................. 95
Connectors and Terminals ............................................................................................................................ 96
Twisted/Shielded Cable Repair................................................................................................................. 96
Twisted Leads Repair................................................................................................................................ 97
Micro-Pack ................................................................................................................................................. 98
Metri-Pack ................................................................................................................................................. 99
Remove .................................................................................................................................................. 99
iii
Table of Contents Electronic Controlled LPG/Gasoline Fuel System

Weather-Pack .......................................................................................................................................... 100
Weather-Pack Terminal Repair.......................................................................................................... 101
This section is for the following models:
H2.00-3.20XM (H40-65XM) [H177];

S2.00-3.20XM (S40-65XM) [D187];
H3.50-5.50XM (H70-120XM) [L005];
H6.00-7.00XL (H135-155XL, H135-155XL 2) [G006];
S6.00-7.00XL (S135-155XL, S155XLS, S135-155XL 2) [C024];
S3.50-5.50XM (S70-120XM) [F004]
iv
900 SRM 1088 General
General
This section has the description, operation, and re- underground ventilation systems. Propane is
pair procedures for the parts of the LPG and gasoline heavier than air and can displace oxygen, cre-
fuel systems used on the GM 3.0L and 4.3L engines. ating a dangerous condition.
Special service tools shown in this service manual

that have tool product numbers beginning with “J” CAUTION
or “BT” are available for world wide distribution from Less severe than a WARNING, but has the po-
Kent-Moore Tools. tential to cause injury or damage to equipment.
Also used to notify of situations that could lead
FUEL SYSTEM WARNINGS AND to eventual failure, injury or damage.
CAUTIONS
It is important to note that this manual contains var-
CAUTION
ious Warnings, Cautions, and Notes that must be Late model engines use a combination of stan-
carefully observed in order to reduce the risk of per- dard and metric fasteners. The components
sonal injury during service or repair. Improper ser- affected are the starter motor, engine mounts,
vice or repair may damage the engine or render it un- and flywheel housing mounting. Other compo-
safe or fail to make the engine emissions compliant. nents may also have a combination of fasten-
It is also important to warn of all hazardous conse- ers. Always verify that the proper fasteners are
quences that might result from careless treatment of used whenever removing or replacing any com-
the engine. Failure to observe these items could in- ponents.
fluence terms of the warranty.
To reduce the chance of personal injury and/or prop-
erty damage, the following instructions must be care-
WARNING fully observed.
Failure to heed could result in death, injury, or • Proper service and repair are important to the
property damage. safety of the service technician and the safe reli-
able operation of all engines. The service proce-
dures recommended and described in this service
WARNING manual are effective methods of performing ser-
Do not smoke, carry lighted tobacco, or use vice and repair. Some of these procedures require
a lighted flame of any type when working on the use of tools specially designed for the purpose.
or near any fuel related component. Highly • If part replacement is necessary, the replacement
flammable air/fuel mixtures may be present part must be of the same part number or equiva-
and can be ignited causing personal injury. lent part. Do not use a replacement part of lesser
quality. In the case of replacement parts for the
WARNING emission control system use only genuine HYSTER
Do not allow propane to contact the skin. replacement parts.
Propane is stored in the fuel tank as a liquid. • Before using a replacement part, service proce-
When propane contacts the atmosphere, it dure, or a tool which is not recommended by the
immediately expands into a gas, resulting in engine manufacturer, it must first be determined
refrigeration that can cause severe burns. that neither personal safety nor the safe operation
of the engine will be jeopardized by the replace-
ment part, service procedure, or the tool selected.
WARNING
Do not allow propane to accumulate in areas
below ground level such as in a service pit or
1
Glossary 900 SRM 1088
Glossary
AVV - Air Valve Vacuum. The vacuum signal taken BTU - British Thermal Unit. A measurement of the
from below the air valve assembly and above the amount of energy required to raise the temperature
throttle butterfly. of 0.45 kg (1 lb) of water 0.555 C (1 F).
Active Governor Mode - Speed is governed by one Butane - An odorless, colorless gas, C 4H 10 found in
of two modes. Isochronous, which maintains an exact natural gas and petroleum. One of the five LP gases.
speed, or Droop, which allows speed to drop a prede-
termined amount based on current engine load. CAFE - Corporate Average Fuel Economy.
Adaptive - Ability to compensate and adjust operat- Calibration - Identified as CAL on the diagnostic
ing parameters. tools.
AL - Adaptive Learn. CARB - California Air Resources Board.
AL Mult - Adaptive Learn Multiplier. The adaptive CO - Carbon Monoxide. A chemical compound of a
learn multiplier is a correction to the fuel delivery highly toxic gas that is both, odorless and colorless.
which is expressed as a percentage and stored in the
Carburetor - An apparatus for supplying an inter-
ECM’s RAM.
nal combustion engine a mixture of vaporized fuel
Air/Fuel Ratio - The amount of air and fuel in the and air.
air fuel mixture, which enters the engine, shown in
Cathode Ray Tube - A vaccum tube in which cath-
a ratio.
ode rays, usually in the form of a slender beam, are
Analog - 0 to 5 volt or 0 to 12 volt signals. projected on a fluorescent screen and produce a lumi-
nous spot.
Analog Voltmeter - A meter that uses a needle to
point to a value on a scale of numbers usually of the CHT - Cylinder head temperature.
low impedance type; used to measure voltage and re-
Circuit - A path of conductors through which elec-
sistance.
tricity flows before it returns to its source.
Aromatics - Pertaining to or containing the six-car-
CL - Closed Loop.
bon ring characteristic of the benzene series. Found
in many crude oils. Closed Loop Operation - Applies to systems utiliz-
ing an oxygen sensor. In this mode of operation, the
Backfire - Combustion of the air/fuel mixture in the
system uses oxygen sensor information to determine
intake or exhaust manifolds. A backfire can occur if
air/fuel ratio. Adjustments are made accordingly and
the intake or exhaust valves are open when there is
checked by comparing the new oxygen sensor to pre-
a mis-timed ignition spark.
vious signals. No stored information is used.
BATT - Battery voltage.
CNG - Compressed Natural Gas.
Benzene - An aromatic (C 6H 6). Sometimes blended
CKP - Crankshaft Position Sensor.
with gasoline to improve antiknock value. Benzene
is toxic and suspected of causing cancer. CMP - Camshaft Position Sensor.
Bi-Fueled - A vehicle equipped to run on two fuels Conductor - A material, normally metallic, that
at the same time such as a fumigated diesel. permits easy passage of electricity.
Blow-By - Gases formed by the combustion of fuel Contaminants - Impurities or foreign material
and air, which ordinarily should exert pressure only present in fuel.
against the piston crown and first compression ring.
When rings do not seal, these gases (blow-by) escape Control Module - One of several names for a solid
down the side of the piston into the crankcase. state microcomputer which monitors engine condi-
tions and controls certain engine functions; i.e. air/
BP - Barometric Pressure. The pressure of the out- fuel ratio, injection and ignition time, etc.
side air.
2
900 SRM 1088 Glossary
Converter - A LPG fuel system component contain- FTV - Fuel Trim Valve.
ing varying stages of fuel pressure regulation com-
bined with a vaporizer. FFV - Flexible Fuel Vehicle.
Cryogen - A refrigerant used to obtain very low tem- Firing Line - The portion of an oscilloscope pattern
peratures. that represents the total amount of voltage being ex-
pended through the secondary circuit.
Current - The directed flow of electrons through a
conductor. Measured in amps. FPP - Foot Pedal Position Sensor.
Dedicated Fuel System - A motor fuel system de- Fuel Injector - A spring-loaded, electromagnetic
signed to operate on only one fuel type. valve which delivers fuel into the intake manifold,
in response to an electrical pulse or signal from the
Diaphragm - A thin, flexible membrane that sep- control module.
arates two chambers. When the pressure in one
chamber is lower than in the other chamber, the Fuel Lock - A solenoid-controlled valve located in
diaphragm will move toward the side with the low the fuel line to stop the flow when the engine stops
pressure. or the ignition switch is OFF.
Diaphragm Port - The external port located at the Gasohol - 10 percent ethanol, 90 percent gasoline.
fuel inlet assembly and connected to the vacuum Often referred to as E-10.
chamber above the air valve diaphragm.
Gasoline - A motor vehicle fuel that is a complex
DVOM - Digital Volt/Ohmmeter. A meter that uses a blend of hydrocarbons and additives. Typical octane
numerical display in place of a gauge and is usually level is 89.
of the high impedance type.
Greenhouse Effect - A scientific theory that sug-
DTC - Diagnostic Trouble Code. gests that excessive levels of carbon dioxide from the
burning of fossil fuels is causing the atmosphere to
ECT - Engine Coolant Temperature. trap heat and cause global warming.
ECM - Electronic Control module. HD 10 - A fuel of not less than 80 percent liquid vol-
ume propane and not more than 10 percent liquid vol-
EFI - Electronic Fuel Injection. A fuel injection sys- ume propylene.
tem which uses a microcomputer to determine and
control the amount of fuel, required by and injected HD 5 - A fuel of not less than 90 percent liquid vol-
into, a particular engine. ume propane and not more than 5 percent liquid vol-
ume propylene.
EGR - Exhaust gas recirculation.
HEGO - Heated Oxygen Sensor.
EPA - Environmental Protection Agency: A regulat-
ing agency of the Federal government which, among HDV - Heavy Duty Vehicle.
other duties, establishes and enforces automotive
emissions standards. Hg - Chemical symbol for mercury. Used in reference
to vacuum (in. of Hg).
Ethanol - Grain alcohol (C 2H 5OH), generally pro-
duced by fermenting starch or sugar crops. Hydrocarbon - A chemical compound made up of
hydrogen and carbon (HC). A major pollution emis-
EEC - Evaporative Emissions Controls. An automo- sion of the internal combustion engine. Gasoline and
tive emission control system designed to reduce hy- almost all other fuels are hydrocarbons.
drocarbon emissions by trapping evaporated fuel va-
pors from the fuel system. Hydrostatic Relief Valve - A pressure relief device
installed in the liquid propane hose on a propane fuel
Excess Flow Valve - A check valve that is caused system.
to close by the fuel when the flow exceeds a predeter-
mined rate. IAT - Intake Air Temperature.
3
Glossary 900 SRM 1088
Ideal Mixture - The air/fuel ratio at which the best MAP - Manifold Absolute Pressure. The pressure of
compromise of engine performance to exhaust emis- the air in the intake manifold.
sions is obtained. Typically 14.7:1 for gasoline and
15.6:1 for LPG. MAT - Manifold Air Temperature. The temperature
of the air in the intake manifold.
Ignition Reserve - The difference between avail-
able voltage and the required voltage. M85 - A blend of gasoline and methanol consisting of
85 percent methanol and 15 percent gasoline.
IMPCO - Imperial Machine Products Company. IM-
PCO Technologies, Inc. A manufacturer of both LPG Measurements of Pressure - 1 PSI=2.06 Hg (mer-
and Gasoline fuel systems. cury)=27.72 in. H 2O (water column). At sea level
atmospheric pressure is 29.92 in. Hg.
Impedance - A form of opposition of AC current flow
(resistance) measured in ohms. Methanol: Known as wood alcohol (CH 3OH), a
light, volatile, flammable alcohol commonly made
Insulation - A non-conductive material used to from natural gas.
cover wires in electrical circuits to prevent the
leakage of electricity and to protect the wire from MIL - Malfunction Indicator Lamp. A dash mounted
corrosion. light that illuminates when the ECM senses a system
fault.
Intercept - An electrical term for a type of splice
where the original circuit is interrupted and redi- Misfire - Failure of the air/fuel mixture to ignite dur-
rected through another circuit. ing the power stroke.
IVS - Idle Validation Switch. Mixer - Fuel introduction device that does not in-
clude a throttle plate.
ITK - IMPCO Test Kit.
MPFI - Multi-Point Fuel injection. A fuel injection
Knock - Sound produced when an engine’s air/fuel system that uses one injector per cylinder mounted
mixture is ignited by something other than the spark on the engine to spray fuel near the intake valve area
plug, such as a hot spot in the combustion chamber. of combustion chamber.
Can be caused by a fuel with an octane rating that
is too low or maladjusted ignition timing. Also called MTBE - Methyl Tertiary Butyl Ether. Oxygenate
detonation or ping. added to gasoline to reduce harmful emissions and
to improve the octane rating.
Lambda Sensor - A feedback device, usually located
in the exhaust manifold, which detects the amount Natural Gas - A gas formed naturally from buried
of oxygen present in exhaust gases in relation to the organic material, composed of a mixture of hydrocar-
surrounding atmosphere. bons, with methane (CH 4) being the dominant com-
ponent.
Lean Mixture - An air to fuel ratio above the stoi-
chiometric ratio; too much air. NOx - See Oxides of Nitrogen.
LEV - Low Emission Vehicle. Octane Rating - The measurement of the antiknock
value of a motor fuel.
Limp-in or Limp-home - This term is used to de-
scribe the drivability characteristics of a failed com- Open-Loop - An operational mode during which
puter system. control module memory information is used to deter-
mine air/fuel ratio, injection timing, etc., as opposed
LPG - Liquefied Petroleum Gas. A fuel commonly to actual oxygen sensor input.
known as propane consisting mostly of propane
(C 3H 8), derived from the liquid components of nat- Orifice - A port or passage with a calibrated open-
ural gas stripped out before the gas enters the ing designed to control or limit the amount of flow
pipeline, and the lightest hydrocarbons produced through it.
during petroleum refining. Octane level is 107.
Oscilloscope - An instrument that converts voltage
LPL - Low pressure lock-off. and frequency readings into traces on a cathode-ray
tube.
4
900 SRM 1088 Glossary
Oxides of Nitrogen - Chemical compounds of nitro- Reactivity - Refers to the tendency of an HC in the
gen bonded to various amounts of oxygen (NOx). A presence of NOx and sunlight to cause a smog-form-
chief smog-forming agent. ing reaction. The lighter the HC, the lower reactivity
tends to be.
Oxygen Sensor - An automotive sensor that pro-
duces a signal in accordance with the oxygen content Regulator - An assembly used to reduce and control
of the exhaust gas. See Lambda Sensor. the pressure of a liquid or vapor.
Oxygenate - MTBE, ethanol, and methanol. Oxy- Resistance - The opposition to the flow of current in
genates are added to gasoline to increase the oxygen an electrical circuit. Measured in ohms.
content and therefore reduce exhaust emissions.
Rest Pressure - Fuel pressure maintained within
O-zone - A radical oxygen module (O 3) that is found the system after engine shutdown.
in the upper atmosphere and filters out ultravio-
let radiation from the sun. Ground level o-zone is Rich Mixture - An air to fuel ratio below the stoi-
formed by NOx during the formation of photochemi- chiometric ratio; too much fuel.
cal smog.
SAE - Society of Automotive Engineers.
Particulates - Microscopic pieces of solid or liquid
Secondary Circuit - The high-voltage output side
substances such as lead and carbon that are dis-
of the ignition coil.
charged into the atmosphere by internal combustion
engines. SEFI or SFI - Sequential Electronic Fuel Injection
or Sequential Fuel Injection.
PCV - Positive Crankcase Ventilation. An automo-
tive emission control system designed to reduce hy- Sensors - Devices that provide the control module
drocarbon emissions by routing crankcase fumes into with engine information as needed to properly con-
the intake manifold rather than to the atmosphere. trol engine function.
PFI - Port Fuel Injection. An electromagnetically ac- Spark Line - The portion of an oscilloscope pattern
tuated solenoid fuel injector that injects fuel to each that represents the time during which the air/fuel
intake valve. mixture is being burned in the combustion chamber.
Pressure Differential - The differential between Splice - An electrical term for the joining of two or
atmospheric pressure and intake manifold (referred more conductors at a single point.
to as vacuum) pressure.
Stoichiometric Ratio - An ideal fuel/air ratio for
Pressure Regulator - A device to control the pres- combustion in which all of the fuel and most of the
sure of fuel delivered to the fuel injector(s). oxygen will be burned.
Primary Circuit - The low-voltage or input side of Sulfur Oxides - Chemical compounds where sulfur
the ignition coil. is bonded to varying numbers of oxygen, produced by
the combustion of gasoline or any other fuel that con-
Propane - An odorless, colorless gas, C 3H 8, found in
tains sulfur. As sulfur oxides decompose in the at-
natural gas and petroleum.
mosphere, they combine with water to form sulfuric
PSIA - Pounds per square inch absolute. 14.7 psia = acid.
0 psig.
System Pressure - The fuel pressure maintained in
PTV - Pressure Trim Valve. the system during normal engine operation.
RAM - Random Access Memory. The portion of com- Tap - An electrical term for a type of splice where the
puter memory within the ECM, which changes as the original circuit is not interrupted.
engine is running and is stored while the engine is
TBI - Throttle Body Injection. Any of several injec-
off.
tion systems that have the fuel injector(s) mounted
in a centrally located throttle body.
5
Description and Operation of LPG Fuel System 900 SRM 1088
Throttle Body - Controls engine RPM by adjusting of the mixer, directly exposed to airflow before the
the engine manifold vacuum to the mixer. Consists addition of vaporized LPG.
of housing shaft, throttle liner, and butterfly valve.
VOM - Volt/Ohmmeter. A combination meter used to
TMAP - Combined Air Inlet Temperature and Man- measure voltage and resistance in an electrical cir-
ifold Pressure Sensor. cuit. Available in both analog and digital types. May
be referred to as AVOM and DVOM.
Toluene - A liquid aromatic hydrocarbon C 7H 8.
Voltage - The electrical pressure that causes current
TPS - Throttle Position Sensor. to flow in a circuit. Measured in volts.
TWC - Three-way catalyst used in a converter to re- Voltage Drop - A lowering of the voltage in a circuit
duce exhaust gas emissions of hydro-carbons, car- when resistance or electrical load is added.
bon monoxide, and nitrogen oxide in conjunction with
closed loop fuel control. Xylene - C 6H 4 (CH 3) 2. Any of three toxic flammable
oily isomeric aromatic hydrocarbons that are
Vaporization - A process in which liquid changes dimethyl homologues of benzene and are usually
states into gas. obtained from petroleum or natural gas distillates.
VAVV - Venturi Air Valve Vacuum. An amplified air
valve vacuum signal coming from the venturi area
Description and Operation of LPG Fuel System

PROPANE FUEL SYSTEM module (ECM), fuel trim valve (FTV), pressure trim
valve (PTV), and three-way catalytic (TWC) muffler.
The primary components of the propane fuel system See Figure 1. The system operates at pressures
are the fuel storage tank, low pressure regulator which range from 355.6 mm (14 in.) of water column
(LPR), fuel mixer module with throttle control de- up to 21.5 bar (312 psi).
vice, low pressure lock-off solenoid, electronic control
Legend for Figure 1

A. TANK PRESSURE D. AIR/FUEL MIXTURE
B. REGULATED PRESSURE E. EXHAUST GASES
C. INTAKE AIR
1. FUEL CYLINDER 12. HEATED EXHAUST GAS OXYGEN (HEGO)
2. FUEL FILTER SENSOR
3. LPL 13. THREE-WAY CATALYTIC (TWC) MUFFLER
4. MALFUNCTION INDICATOR LIGHT (MIL) 14. SPEED CONTROL MOTOR
5. ELECTRONIC CONTROL MODULE (ECM) 15. TEMPERATURE MANIFOLD ABSOLUTE
6. FUEL TRIM VALVE (FTV) PRESSURE (TMAP)
7. FOOT PEDAL POSITION SENSOR 16. THROTTLE POSITION SENSOR (TPS)
8. ENGINE COOLANT TEMPERATURE (ECT) 17. THROTTLE BODY
SENSOR 18. MIXER
9. DISTRIBUTOR (TIMING) 19. AIR CLEANER
10. OIL PRESSURE 20. PRESSURE TRIM VALVE (PTV)
11. CRANKSHAFT SENSOR 21. LOW PRESSURE REGULATOR (LPR)
6
900 SRM 1088 Description and Operation of LPG Fuel System
Figure 1. Typical Fuel System Schematic
7
LPG FUEL TANK SERVICE LINE

Propane is stored in the fuel tank as a liquid. The
approximate pressure of the fuel in the tank is CAUTION
16.5 bar (240 psi) when the tank is full at an am- The bulkhead assembly should never be re-
bient temperature of 27 C (81 F). The boiling point moved and a service line run through the
(temperature at which the liquid fuel becomes va- sheet metal.
por) is approximately 40 C ( 40 F). When the fuel
Propane flows from the fuel tank to the electric lock
changes from liquid to vapor, the fuel expands and
via the service line. The service line is connected to
creates pressure inside the tank. When the tank
the tank utilizing a quick coupler. The other end of
service valve is opened, the pressure inside the tank
the service line is connected to a bulkhead connector
forces the liquid fuel out through the pickup tube
mounted on the equipment sheet metal. This bulk-
located near the bottom of the fuel cylinder. Because
head connector allows for a safe means of passing
the propane is stored under pressure, the tank is
through the equipment’s engine compartment sheet
equipped with safety valves which are normally set
metal and into the engine compartment. If a bulk-
at 25.8 bar (375 psi) to prevent tank rupture due
head connector is used, a pressure relief device is
to over pressurization of the cylinder. The service
mounted in the service line or the connector itself to
valve, mounted in the end of the cylinder, controls
prevent over pressurization of the service line. The
the flow of fuel from the tank. By turning the han-
service line is made of high pressure hose with spe-
dle to its open position, fuel flows out of the tank
cial material or possibly tubing which is friendly to
and into the service line. The service valve is also
the LPG fuel and should always be replaced with a
equipped with a safety feature called an excess flow
HYSTER approved part.
check valve. This feature reduces the flow from the
service valve in the event of a rupture of the fuel
FUEL FILTER
line or any down stream component. See Figure 2
for fuel tank components. Propane fuel, like all other motor fuels, is subject
to contamination from outside sources. Refueling of
the equipment’s tank and removal of the tank from
the equipment can inadvertently introduce dirt and
other foreign matter into the fuel system. It is there-
fore necessary to filter the fuel prior to entering the
fuel system components down stream of the tank. An
in-line fuel filter has been installed in the fuel sys-
tem to remove the dirt and foreign matter from the
fuel. See Figure 3. The in-line filter is replaceable
as a unit only. Maintenance of the filter is critical
to proper operation of the fuel system and should be
replaced as defined in the Periodic Maintenance
1. LIQUID OUTAGE VALVE WITH QUICK
DISCONNECT COUPLING section for your lift truck. In severe operating condi-
2. FILLER VALVE tions, more frequent replacement of the filter may be
3. PRESSURE RELIEF VALVE necessary.
4. LIQUID OUTAGE FILL CHECK VALVE
5. FUEL GAUGE
6. VAPOR WITHDRAWAL TUBE (WHEN
APPLICABLE)
7. 80 PERCENT LIMITER TUBE
8. FUEL LEVEL FLOAT
9. LIQUID WITHDRAWAL TUBE
Figure 2. Typical Propane Cylinder
1. FUEL FLOW
Figure 3. In-Line Fuel Filter
8
LOW PRESSURE LOCK-OFF (LPL) Propane fuel enters the primary port of the LPR
and passes through the primary jet and into the
The LPL is an electric lock-off device. The electric primary/exchanger chamber. As the propane passes
lock assembly is a 12-volt normally closed valve. The through the heat exchanger, the fuel expands and
solenoid is mounted to the valve body. See Figure 4. creates pressure inside the chamber. The pressure
When energized, the solenoid opens the valve and rises as the fuel expands. When the pressure rises
allows the propane fuel to flow through the device. above 10.34 kPa (1.5 psi), sufficient pressure is
The valve opens during cranking and run cycles of exerted on the primary diaphragm to cause the
the engine. The lock-off supply voltage is controlled diaphragm plate to pivot and press against the pri-
by the ECM. mary valve pin thus closing off the flow of fuel. This
action causes the flow of fuel into the regulator to
LOW PRESSURE REGULATOR (LPR) be regulated. When the engine is cranking, suffi-
cient vacuum will be introduced into the secondary
CAUTION chamber from the mixer, drawing the secondary
The LPR is an emission control device. Compo- diaphragm down onto the spring-loaded lever and
nents inside the regulator are specifically cal- opening the secondary valve allowing vaporized
ibrated to meet the engine emissions require- fuel to pass to the mixer. Increased vacuum in the
ments and should never be disassembled or re- secondary chamber increases the downward action
built. If the LPR fails to operate, replace with on the secondary lever causing it to open wider,
a HYSTER approved part. allowing more fuel to flow to the mixer.
The LPR is a combination vaporizer, pressure-regu- The regulator, utilized on this emission-certified
lating device. The LPR is a negative pressure two- engine, is equipped with a PTV which is directly
stage regulator that is normally closed when the en- mounted to the regulator. See Figure 4. This so-
gine is not running. When the engine is cranking or lenoid is a 12-volt normally closed solenoid. The
running, a partial vacuum is created in the fuel line function of this solenoid is to regulate a specific
which connects the regulator to the mixer. This par- amount of venturi vacuum to the atmospheric side
tial vacuum opens the regulator, permitting fuel to of the secondary diaphragm. By introducing vacuum
flow to the mixer. See Figure 4. to the top side of the secondary diaphragm during
regulator operation, the amount of fuel being de-
livered to the mixer can be trimmed or reduced to
allow for correction to the air/fuel ratio for closed
loop fuel control. The solenoid receives a reference
signal from the ECM which causes the solenoid to be
pulsed fast or slow depending on the amount of fuel
to be trimmed.
AIR FUEL MIXER
CAUTION
The air/fuel mixer is an emission control de-
vice. Components inside the mixer are specifi-
cally calibrated to meet the engines emissions
requirements and should never be disassem-
bled or rebuilt. If the mixer fails to operate,
replace with a HYSTER approved part.
The air valve mixer is an air/fuel metering device

and is completely self-contained. The mixer is an air
1. LPL valve design, utilizing a relatively constant pressure
2. PRESSURE TRIM VALVE (PTV) drop to draw fuel into the mixer from cranking to full
load. The mixer is mounted in the air stream ahead
Figure 4. Low Pressure Regulator and LPL of the throttle control device. See Figure 5.
9
When the engine begins to crank, it draws in air with The mixer is equipped with a low speed mixture ad-
the air valve covering the inlet, and negative pres- justment, which is retained in a tamper-proof hous-
sure begins to build. This negative pressure signal ing. The mixer has been preset at the factory and
is communicated to the top of the air valve chamber should not require any adjustment. In the event that
through four vacuum ports in the air valve assembly. the idle adjustment should need to be adjusted, refer
A pressure/force imbalance begins to build across the to the LPG Fuel System Repair section of this man-
air valve diaphragm between the air valve vacuum ual.
chamber and the atmospheric pressure below the di-
aphragm. The air valve vacuum spring is calibrated THROTTLE CONTROL DEVICE
to generate from 101.6 mm (4 in.) of water column at
start to as high as 355.6 mm (14 in.) of water column Drive By Cable
at full throttle. The vacuum being created is referred
to as air valve vacuum (AVV). As the AVV reaches Engine speed control is maintained by the amount
101.6 mm (4 in.) of water column, the air valve be- of pressure applied to a foot pedal located in the op-
gins to lift against the air valve spring. The amount erator’s compartment. A cable is utilized to connect
of AVV generated is a direct result of the throttle po- the foot pedal to the throttle shaft in the engine com-
sition. At low engine speed, the AVV is low and the partment. A coil spring mounted to the pedal and
air valve position is low, thus creating a small venturi the throttle shaft will keep the throttle shaft in a
for the fuel to flow. As the engine speed increases, the normally closed position. When the foot pedal is de-
AVV increases and the air valve is lifted higher, thus pressed, the throttle shaft is rotated, opening the
creating a much larger venturi. This AVV is commu- butterfly in the venturi of the throttle body allow-
nicated from the mixer venturi to the LPR secondary ing more air and fuel to enter the engine. When the
chamber via the low pressure fuel supply hose. As ECM detects that the engine has reached maximum
the AVV increases in the secondary chamber, the sec- governed speed or requires adjustment for load, the
ondary diaphragm is drawn further down, forcing the ECM will correct the blade position by overriding the
secondary valve lever to open wider. throttle shaft with the electronic governor.
The air fuel mixer is attached to the throttle con-

trol device or throttle body assembly, which is then
connected to the intake manifold of the engine. See
Figure 6. The throttle body maintains control of en-
gine speed by increasing or decreasing the opening
angle of the throttle blade in the throttle body bore,
thus increasing or decreasing the fuel air mixture to
the engine. The throttle blade shaft is connected to
a spring-loaded cable connector which is connected
to the foot pedal in the operator’s compartment. The
shaft incorporates a return spring to insure the blade
position returns to idle when the operator removes
his foot from the pedal. Also attached to the throttle
shaft is a TPS, which provides a signal to the ECM
to indicate the throttle blade angle for speed control
1. MIXER and load control as well as emission control.
2. FOOT PEDAL POSITION (FPP) SENSOR
3. TEMPERATURE MANIFOLD ABSOLUTE Also mounted to the throttle control device is an in-
PRESSURE (TMAP) tegrated electronic governor. The throttle control is
4. ADAPTER TO MANIFOLD maintained by a foot pedal located in the operator’s
5. GOVERNOR MOTOR compartment and connected to the throttle control
6. FUEL TRIM VALVE (FTV) device by a cable. The governor is controlled by the
Figure 5. Air/Fuel Mixer ECM and has no external adjustments. When the
10
ECM determines load adjustment or maximum en- honeycomb coated with a mixture of platinum, pal-
gine speed has been achieved, the governor overrides ladium, and rhodium. The hot gases flow through
the foot pedal and corrects the throttle blade position. the catalyst sections where an oxidation and reduc-
tion reactions take place. These chemical reactions
Also mounted on throttle body assembly is the FTV. reduce the amount of carbon monoxide (CO), hydro-
The FTV is a 12-volt normally closed solenoid valve. carbon (HC), and nitrogen oxide (NOx) in the engines
During closed loop operation, the ECM may send a exhaust. The exhaust gas then flows through the
reference signal to the FTV to open or close to allow outlet.
more or less fuel to be introduced below the throttle
blade to correct the air fuel mixture for proper emis-
sion control.
Figure 7. Three-Way Catalytic Muffler

1. THROTTLE POSITION SENSOR (TPS)
2. GOVERNOR MOTOR ELECTRONIC CONTROL MODULE (ECM)
4. FUEL TRIM VALVE (FTV) To obtain maximum effect from the catalyst and ac-
curate control of the air fuel ratio, the emission cer-
Figure 6. Drive By Cable Throttle body tified engine is equipped with an on-board computer
Assembly or ECM. See Figure 8. The ECM is a 32-bit controller
which receives input data from sensors fitted to the
THREE-WAY CATALYTIC (TWC) MUFFLER engine and fuel system and then outputs various sig-
nals to control engine operation.
The emission certified engine has been designed and
calibrated to meet the emission standards in effect One specific function of the controller is to maintain
for 2004. To help meet the emission requirements, closed loop fuel control. Closed loop fuel control is
the vehicle has been equipped with a TWC muffler. accomplished when the heated exhaust gas oxygen
See Figure 7. The catalyst muffler is a three-way (HEGO) sensor, mounted in the exhaust system,
catalyst, sound damping, and spark arresting unit. sends a voltage signal to the controller. The con-
Besides controlling the noise created from the com- troller then calculates any correction that may need
bustion process and preventing sparks from escaping to be made to the air fuel ratio. The controller then
from the exhaust system, the most important func- outputs signals to the PTV or the FTV or both to
tion is treating the exhaust gases which are created change the amount of fuel being delivered from the
from the combustion process. The TWC consists of a regulator or mixer or to the engine. See Figure 9.
11
The controller also performs diagnostic functions on (ECM) Diagnostic Troubleshooting, GM 3.0L
the fuel system and notifies the operator of malfunc- and 4.3L EPA Compliant Engines 2200 SRM
tions by turning on a malfunction indicator light 1090, can determine the cause of the malfunction.
(MIL) mounted in the dash. Malfunctions in the In the event a technician does not have the comput-
system are identified by a diagnostic code number. erized diagnostic tool, the MIL light can be used to
In addition to notifying the operator of the malfunc- identify the diagnostic code. By following specific
tion in the system, the controller also stores the steps, the technician can activate the blink feature
information about the malfunction in its memory. and count the number of blinks to determine the
A technician can then utilize a computerized diag- diagnostic code number to locate the fault in the
nostic tool to retrieve the stored diagnostic code and system.
by using the section Electronic Control Module
A. INPUTS B. OUTPUTS
1. ELECTRONIC CONTROL MODULE (ECM) 10. BATTERY
2. PRESSURE TRIM VALVE (PTV) 11. MANIFOLD ABSOLUTE PRESSURE (MAP)
3. FUEL TRIM VALVE (FTV) 12. AIR TEMPERATURE (TMAP)
4. LPL VALVE 13. COOLANT TEMPERATURE
5. GOVERNOR SPEED CONTROL 14. OIL PRESSURE
6. TIMING 15. TIMING
7. IGNITION 16. ROTATIONS PER MINUTE (RPM)
8. GAUGES 17. THROTTLE POSITION
9. MALFUNCTION INDICATOR LAMP (MIL) 18. OXYGEN O 2 SENSOR
Figure 8. LPG Electronic Control Module
12
1. ENGINE
2. INPUT HEGO TO ECM
3. ECM CALCULATES THE CHANGE AND COMMAND PTV OR FTV SIGNALS TO INCREASE OR DECREASE
4. OUTPUT PTV OR FTV PULSE INCREASES OR DECREASES FUEL DELIVERY TO THE ENGINE
Figure 9. LPG Closed Loop Control Schematic
13
Description and Operation of Gasoline Fuel System 900 SRM 1088
HEATED EXHAUST GAS OXYGEN (HEGO) lean, the ECM will make the mixture rich. The ECM
SENSOR continuously monitors the HEGO sensor output. If
a rich or lean condition is present for an extended
period of time and the ECM cannot correct the condi-
CAUTION tion, the ECM will set a diagnostic code and turn on
The HEGO sensor is an emissions control com- the MIL light in the dash. See Figure 10.
ponent. If the HEGO sensor fails to operate,
replace only with a HYSTER approved part.
The HEGO sensor is sensitive to silicone and
silicone-based products and can become con-
taminated. Avoid using silicone sealers or
hoses treated with silicone lubricant in the air
stream or fuel supply lines.
The HEGO sensor is mounted in the exhaust sys-

tem downstream of the engine. The HEGO sensor is
used to measure the amount of oxygen present in the
exhaust stream and communicate that to the ECM
through an electrical signal. The amount of oxygen
present in the exhaust stream indicates whether the
fuel air ratio is too rich or too lean. If the HEGO
sensor signal indicates that the exhaust stream is Figure 10. Heated Exhaust Gas Oxygen Sensor
too rich, the ECM will decrease or lean the fuel mix-
ture during engine operation. If the mixture is too
Description and Operation of Gasoline Fuel System

GASOLINE FUEL SYSTEM THROTTLE fuel filter, throttle body, fuel pressure regulator, fuel
BODY INJECTION (TBI), 3.0L ENGINE injector, O 2 sensor, electronic control module (ECM),
ONLY and three-way catalytic (TWC) muffler. See Fig-
ure 11.
The primary components of the gasoline TBI fuel
system are the gasoline fuel tank, electric fuel pump,
Legend for Figure 11

A. AIR FUEL MIXTURE D. GASOLINE RETURN
B. FRESH AIR E. GASOLINE FUEL PRESSURE
C. EXHAUST GASES F. FUEL PUMP PRESSURE
1. FUEL TANK 12. THROTTLE POSITION SENSOR (TPS)
2. MALFUNCTION INDICATOR LIGHT (MIL) 13. SPEED CONTROL MOTOR
3. ELECTRONIC CONTROL MODULE (ECM) 14. TEMPERATURE MANIFOLD ABSOLUTE
4. THREE-WAY CATALYTIC (TWC) MUFFLER PRESSURE (TMAP)
5. OXYGEN (O 2) SENSOR 15. THROTTLE BODY
6. OIL PRESSURE SENSOR 16. INJECTOR
7. CRANKSHAFT SENSOR 17. AIR INDUCTION
8. DISTRIBUTOR 18. AIR CLEANER
9. ENGINE COOLANT TEMPERATURE (ECT) 19. PRESSURE REGULATOR
SENSOR 20. FUEL PRESSURE SENDER
10. ENGINE 21. FUEL FILTER
11. FOOT PEDAL POSITION (FPP) SENSOR 22. FUEL PUMP
14
900 SRM 1088 Description and Operation of Gasoline Fuel System
Figure 11. Gasoline Throttle Body Injection System
15
GASOLINE MULTI-POINT FUEL INJECTION pump with anything other than the HYSTER
(MPFI) SYSTEM, 4.3L ONLY approved replacement could cause damage to
the fuel system and or damage to the fuel tank.
The primary components of the gasoline MPFI fuel
system are the gasoline fuel tank, electric fuel pump, The gasoline is stored as a liquid in the fuel tank and
fuel filter, fuel rails, fuel pressure regulator, fuel in- is drawn into the fuel system by a 12-volt electric fuel
jector, O 2 sensor, fuel pressure manifold, electronic pump. Depending on the vehicle application, the fuel
control module (ECM), and three-way catalytic pump may be mounted in the fuel tank or as a stand-
(TWC) muffler. See Figure 12. alone component. In either case, the fuel pump will
receive a signal from the ECM at key ON to prime
GASOLINE FUEL STORAGE TANK the fuel system for approximately 2 seconds prior to
start. Priming of the fuel system provides a quicker
The gasoline fuel storage tank location may vary on start when the engine begins to crank.
equipment applications. The fuel tank may be in-
tegrated into the chassis frame or may be a stand- FUEL FILTER
alone vessel mounted on the equipment. For precise
location for the equipment application, refer to the After the fuel is drawn into the fuel pump, the fuel
Frame section of your lift truck. then flows through the gasoline fuel filter. The fuel
filter will trap small particles as the fuel passes
GASOLINE FUEL PUMP through the filter to remove debris and prevent in-
jectors from becoming damaged. Maintenance of the
fuel filter is required as indicated in the Periodic
CAUTION Maintenance section for your lift truck. A more
The fuel pump is an emissions control compo- frequent replacement of the filter may be required if
nent. If the fuel pump fails to operate, replace the equipment operates in a dusty or dirty environ-
only with a HYSTER approved part. The ment.
fuel pump is calibrated to supply the correct
amount of fuel to the injectors. Replacing the

A. AIR FUEL MIXTURE D. GASOLINE RETURN
B. FRESH AIR E. GASOLINE FUEL RAIL PRESSURE
C. EXHAUST GASES F. FUEL PUMP PRESSURE
1. FUEL TANK 12. INJECTOR
2. MALFUNCTION INDICATOR LIGHT (MIL) 13. FOOT PEDAL POSITION SENSOR
3. ELECTRONIC CONTROL MODULE (ECM) 14. THROTTLE BODY
4. THREE-WAY CATALYTIC (TWC) MUFFLER 15. SPEED CONTROL MOTOR
5. OXYGEN (O 2) SENSOR 16. TEMPERATURE MANIFOLD ABSOLUTE
6. ENGINE PRESSURE (TMAP)
7. OIL PRESSURE SENSOR 17. THROTTLE POSITION SENSOR (TPS)
8. CRANKSHAFT SENSOR 18. AIR INDUCTION
9. DISTRIBUTOR 19. AIR CLEANER
10. ENGINE COOLANT TEMPERATURE (ECT) 20. PRESSURE REGULATOR
SENSOR 21. FUEL FILTER
11. MANIFOLD 22. FUEL PUMP
16
Figure 12. Gasoline Multi-Point Fuel Injection System
17
FUEL PRESSURE REGULATOR, 3.0L The fuel pressure regulator has no adjustments and
ONLY is integrated into the fuel rail assembly. See Fig-
ure 14. The fuel rail also contains a Schrader valve
The fuel flows from the fuel filter to the throttle body which is utilized to test the regulated pressure of the
injector unit where the fuel is regulated. During en- fuel system.
gine operation, the regulator maintains the proper
amount of gasoline to the top of the injector. During
lower rpm operation, excess fuel at the top of the in-
jector is bypassed and returned to the fuel tank for
recirculation. The fuel pressure regulator has no ad-
justments and is integrated into the throttle body in-
jector unit. See Figure 13.
1. SCHRADER VALVE
2. PRESSURE REGULATOR
3. FUEL RAIL
Figure 14. Fuel Rail Assembly
FUEL INJECTOR
The fuel supply is maintained on the top of the injec-
tor by the fuel pressure regulator. The injector is fed
a pulse signal through the wire harness which causes
the injector to open. During regular operating con-
ditions, the ECM controls the duration of opening of
the injector. During lower rpm operation, the injector
1. INJECTOR PRESSURE REGULATOR signals or pulses are less frequent than when the en-
ASSEMBLY gine is operating at higher rpms. The certified engine
2. THROTTLE BODY INJECTOR UNIT has been calibrated to deliver the precise amount of
3. FUEL RETURN OUTLET
4. FUEL INLET fuel for optimum performance and emission control.
Figure 13. Throttle Body Injector Unit THROTTLE CONTROL DEVICE
FUEL RAIL AND PRESSURE REGULATOR, Drive By Cable

4.3L ONLY Engine speed control is maintained by the amount
The fuel flows from the fuel filter to the fuel rails of pressure applied to a foot pedal located in the
where the fuel is regulated. During engine opera- operator’s compartment. A cable is utilized to con-
tion, the regulator maintains the proper amount of nect the foot pedal to the throttle shaft in the engine
fuel pressure to the top of the injector. During lower compartment. A coil, spring-mounted to the pedal
rpm operation, excess fuel at the top of the injector is and the throttle shaft, will keep the throttle shaft in
bypassed and returned to the fuel tank for recircula- a normally closed position. When the foot pedal is
tion.
18
depressed, the throttle shaft is rotated opening the maintained by a foot pedal located in the operator’s
butterfly in the venturi of the throttle body allowing compartment and connected to the throttle control
more air and fuel to enter the engine. When the device by a cable. The governor is controlled by the
ECM detects that the engine has reached maximum ECM and has no external adjustments. When the
governed speed or requires adjustment for load, the ECM determines load adjustment or maximum en-
ECM will correct the blade position by overriding gine speed has been achieved, the governor overrides
the throttle shaft with the electronic governor. the foot pedal and corrects the throttle blade position.
The throttle control device or throttle body assem- THREE-WAY CATALYTIC MUFFLER
bly is connected to the intake manifold of the engine.
See Figure 15. The throttle body maintains control The emission-certified engine has been designed and
of engine speed by increasing or decreasing the open- calibrated to meet the emission standards in effect
ing angle of the throttle blade in the throttle body for 2004. To help meet the emission requirements,
bore thus increasing or decreasing the intake air to the vehicle has been equipped with a TWC muffler.
the engine. The throttle blade shaft is connected to See Figure 16. The catalyst muffler is a three-way
a spring-loaded cable connector which is connected catalyst, sound damping, and spark arresting unit.
to the foot pedal in the operator’s compartment. The Besides controlling the noise created from the com-
shaft incorporates a return spring to insure the blade bustion process and preventing sparks from escaping
position returns to idle when the operator removes from the exhaust system, the most important func-
his foot from the pedal. Also attached to the throt- tion is treating the exhaust gases which are created
tle shaft is a throttle position sensor (TPS), which from the combustion process. The TWC consists of a
provides a signal to the ECM to indicate the throt- honeycomb coated with a mixture of platinum, palla-
tle blade angle for speed control and load control as dium, and rhodium. The hot gases flow through the
well as emission control. catalyst sections where oxidation and reduction re-
actions take place. These chemical reactions reduce
the amount of carbon monoxide (CO), hydrocarbon
(HC), and nitrogen oxide (NOx) in the engines ex-
haust. The exhaust gas then flows through the out-
let.
1. GOVERNOR MOTOR
Figure 15. Drive By Cable Throttle Body

Assembly
Also mounted to the throttle control device is an in-

tegrated electronic governor. The throttle control is Figure 16. Three-Way Catalytic Muffler
19
ELECTRONIC CONTROL MODULE (ECM) light (MIL) mounted in the dash. Malfunctions
in the system are identified by a diagnostic code
To obtain maximum effect from the catalyst and ac- number. In addition to notifying the operator of
curate control of the air fuel ratio, the emission certi- the malfunction in the system, the controller also
fied engine is equipped with an on-board computer or stores the information about the malfunction in its
ECM. See Figure 17. The ECM is a 32-bit controller memory. A technician can then utilize a computer-
which receives input data from sensors fitted to the ized diagnostic tool to retrieve the stored diagnostic
engine and fuel system and then outputs various sig- code and by using the diagnostic trouble code (DTC)
nals to control engine operation. tables in the section Electronic Control Module
(ECM) Diagnostic Troubleshooting, GM 3.0L
One specific function of the controller is to maintain
and 4.3L EPA Compliant Engines 2200 SRM
closed loop fuel control. Closed loop fuel control is ac-
1090, determine the cause of the malfunction. In the
complished when the HEGO sensor mounted in the
event a technician does not have the computerized
exhaust system sends a voltage signal to the con-
diagnostic tool, the MIL light can be used to identify
troller. The controller then calculates any correction
the diagnostic code. By following specific steps, the
that may need to be made to the air fuel ratio. See
technician can activate the blink feature and count
Figure 18.
the number of blinks to determine the diagnostic
The controller also performs diagnostic functions code number to locate the fault in the system.
on the fuel system and notifies the operator of mal-
functions by turning on a malfunction indicator
A. INPUTS B. OUTPUTS
1. ELECTRONIC CONTROL MODULE (ECM) 10. MANIFOLD ABSOLUTE PRESSURE (MAP)
2. FUEL PUMP 11. AIR TEMPERATURE (TMAP)
3. GOVERNOR SPEED CONTROL 12. COOLANT TEMPERATURE
4. FUEL INJECTOR 13. OIL PRESSURE
5. TIMING 14. TIMING
6. IGNITION 15. RPM
7. GAUGES 16. THROTTLE POSITION
8. MALFUNCTION INDICATOR LAMP (MIL) 17. OXYGEN (O 2) SENSOR
9. BATTERY
Figure 17. Gasoline Electronic Control Module
20
1. ENGINE
2. INPUT HEGO SENSOR TO ECM
3. ECM CALCULATES THE CHANGE AND COMMANDS INJECTOR SIGNAL TO INCREASE OR DECREASE
4. OUTPUT INJECTOR PULSE INCREASES OR DECREASES FUEL DELIVERY TO THE ENGINE
Figure 18. Gasoline Closed Loop Control Schematic
HEATED EXHAUST GAS OXYGEN (HEGO) The HEGO sensor is mounted in the exhaust sys-
SENSOR tem downstream of the engine. See Figure 19. The
HEGO sensor is used to measure the amount of oxy-
gen present in the exhaust stream and communicates
CAUTION that to the ECM via an electrical signal. The amount
The HEGO sensor is an emissions control com- of oxygen present in the exhaust stream indicates
ponent. If the HEGO sensor fails to operate, whether the fuel air ratio is too rich or too lean. If
replace only with a HYSTER approved part. the HEGO sensor signal indicates that the exhaust
The HEGO sensor is sensitive to silicone and stream is too rich, the ECM will decrease or lean
silicone-based products and can become con- the fuel mixture by reducing the signals to the in-
taminated. Avoid using silicone sealers or jectors during engine operation. If the mixture is too
hoses treated with silicone lubricant in the air lean, the ECM will richen the mixture or increase the
stream or fuel supply lines.
21
LPG Fuel System Repair 900 SRM 1088
pulse to the injectors. The ECM continuously moni-

tors the HEGO sensor output. If a rich or lean condi-
tion is present for an extended period of time and if
the ECM cannot correct the condition, the ECM will
set a diagnostic code and turn on the MIL light in the
dash.
Figure 19. Heated Exhaust Gas Oxygen Sensor
LPG Fuel System Repair

PROPANE FUEL SYSTEM PRESSURE PROPANE FUEL SYSTEM LEAK TEST
RELIEF
WARNING
WARNING Never use an open flame of any type to check
The propane fuel system operates at pressures for propane fuel system leaks.
up to 21.5 bar (312 psi). To minimize the risk
Always inspect the propane fuel system for leaks af-
of fire and personal injury, relieve the propane
ter performing service. Check for leaks at the fittings
fuel system pressure (where applicable) before
of the serviced or replaced component. Use a com-
servicing the propane fuel system components.
mercially available liquid leak detector or an elec-
tronic leak detector. When using both methods, use
WARNING the electronic leak detector first to avoid contamina-
Never use an open flame of any type when re- tion by the liquid leak detector.
lieving fuel system pressure.
PROPANE FUEL FILTER REPLACEMENT
CAUTION Remove
Residual vapor pressure will be present in the
fuel system. Ensure the work area is well ven- 1. Relieve the propane fuel system pressure. Refer
tilated before disconnecting any fuel line. to Propane Fuel System Pressure Relief.
To relieve propane fuel system pressure: 2. Disconnect the negative battery cable.
1. Close the manual shutoff valve (MSV) on the 3. Slowly loosen the fuel inlet fitting to the filter
propane fuel tank. and remove the fuel line.
2. Start and run the vehicle until the engine stalls. 4. Remove the outlet fitting from the filter.
3. Turn the ignition switch OFF. 5. Remove the filter from the retaining bracket and
discard.
22
900 SRM 1088 LPG Fuel System Repair
Install 1. Relieve the propane fuel system pressure. Refer

to Propane Fuel System Pressure Relief.
CAUTION 2. Disconnect the negative battery cable.
Be sure to install the filter in the correct direc-
tion of the flow marked with an arrow. See Fig- 3. Disconnect the LPL electrical connector.
ure 20.
4. Disconnect the LPG fuel inlet line from the LPL
inlet fitting.
CAUTION
Do not use Teflon tape on the fuel line fittings. 5. Unscrew the LPL from the LPR inlet fitting.
Use only a liquid pipe sealant.
Install
1. Install the filter to the retaining bracket and se-
cure. See Figure 21 for the following steps:
CAUTION
Do not use Teflon tape on any fuel fitting. Use
a liquid pipe thread sealant when installing fit-
tings.
1. Apply pipe thread sealant to the LPR inlet fit-

ting.
2. Install the LPL to the LPR. Tighten the LPL fin-

1. FUEL FLOW ger tight plus 1 to 2 turns and place the LPL in
the correct position.
Figure 20. In-line Fuel Filter
3. Install the fuel inlet line.
2. Install the outlet fuel line and torque to 27 N•m
(20 lbf ft). 4. Tighten the fuel line fitting to the LPL and torque
to 27 N•m (20 lbf ft).
3. Install the inlet fuel line.
5. Connect the LPL electrical connector.
4. Connect the negative battery cable.
5. Open manual shutoff valve.
7. Open the tank manual shutoff valve.
6. Start the vehicle and leak check the propane fuel
system at each serviced fitting. Refer to Propane 8. Start the vehicle and check the propane fuel sys-
Fuel System Leak Test. tem for leaks at each serviced fitting. Refer to
Propane Fuel System Leak Test.
LOW PRESSURE LOCK-OFF (LPL)
REPLACEMENT
Remove
See Figure 21 for the following steps:
23
NOTE: * IS FOR 3.0L ONLY.

1. LPL 8. COOLANT FITTING
2. INLET FITTING TO LPL 9. VAPOR OUTLET FITTING
3. ELBOW FITTING 10. MOUNTING BOLTS
4. LOW PRESSURE REGULATOR 11. FITTING RETAINING PINS
5. PTV 12. SECONDARY TEST PORT CAP
6. PTV LOCKING CLAMP 13. ORIFICE, COOLANT RESTRICTOR
7. PTV BOLTS
Figure 21. Low Pressure Regulator Assembly
24
PRESSURE TRIM VALVE (PTV) 5. Remove the PTV. Refer to Pressure Trim Valve
REPLACEMENT (PTV) Replacement, Remove.
Remove 6. Disconnect the supply and return coolant lines

from the LPR.
7. Remove the coolant inlet and outlet fitting re-
1. Disconnect the PTV electrical connection. taining pins.
2. Remove the vacuum hose from the PTV. 8. Remove the inlet fitting.
3. Remove two bolts and retaining plate. 9. Remove the outlet fitting. For the 3.0L, locate
the coolant line orifice in the housing or attached
4. Remove the PTV. to the fitting and retain.
Install 10. Disconnect the FTV supply line.
See Figure 21 for the following steps: 11. Loosen the two LPR mounting bolts.
NOTE: Apply a small amount of O-ring lubricant to 12. Lift LPR assembly and remove the two LPR
the PTV O-ring before installation. mounting bolts.
1. Install the PTV using the two mounting bolts and 13. Loosen the fuel vapor hose clamp at the LPR fuel
retaining plate. outlet fitting.
2. Tighten bolts and torque to 9 N•m (80 lbf in). 14. Disconnect the fuel vapor hose from the LPR out-
let fitting and remove the LPR.
3. Connect the PTV vacuum line.
15. Remove the retaining pin from the vapor outlet
4. Connect the PTV electrical connector. fitting.
5. Start the vehicle and check the propane fuel sys- 16. Remove the vapor outlet fitting from the LPR.
tem for leaks at each serviced fitting. Refer to
Propane Fuel System Leak Test. 17. Remove the LPR.
6. Connect the laptop computer and verify the en- Install

gine is operating in closed loop and no MIL light
is present. See the section Electronic Control See Figure 21 for the following steps:
Module (ECM) Diagnostic Troubleshooting,
GM 3.0L and 4.3L EPA Compliant Engines CAUTION
2200 SRM 1090.
Do not use Teflon tape on any fuel fitting. Use
a liquid pipe thread sealant when installing fit-
LOW PRESSURE REGULATOR
tings.
Remove
CAUTION
For the 3.0L, be sure to install regulator coolant
1. Relieve the propane fuel system pressure. Refer line orifice into the return side of the LPR wa-
to Propane Fuel System Pressure Relief. ter outlet before installing the return line hose
fitting.
2. Disconnect the negative battery cable.
NOTE: Lubricate the O-rings on each of the fittings.
3. Clamp the coolant hoses to the LPR or drain the
radiator. 1. Install the inlet water fitting and secure with re-
taining pin.
4. Remove the LPL. Refer to Low Pressure Lock-Off
(LPL) Replacement, Remove. 2. For the 3.0L, install the outlet coolant line orifice.
25
3. Install outlet fitting and secure with retaining FUEL TRIM VALVE (FTV) SOLENOID
pin. REPLACEMENT
4. Install vapor outlet fitting and secure with re- Remove
taining pin.
See Figure 22 for the 3.0L, Figure 23 for the 4.3L, for
5. Insert the vapor hose to the fuel outlet fitting and the following steps:
place clamp.
1. Disconnect the FTV electrical connection.
6. Install the FTV supply line and secure.
2. Remove the fuel supply hose from the FTV.
7. Secure the LPR to the mounting bracket using
the two retaining bolts and torque to 14 N•m 3. Remove the two retaining bolts.
(10 lbf ft).
4. Remove the FTV.
8. Install the water inlet and outlet lines to the fit-
tings and place clamps. Install
9. Install LPL. Refer to Low Pressure Lock-Off See Figure 22 for the 3.0L, Figure 23 for the 4.3L, for
(LPL) Replacement, Install. the following steps:
10. Install the PTV. Refer to Pressure Trim Valve NOTE: Apply a small amount of O-ring lubricant to
(PTV) Replacement, Install. the FTV O-ring before installation.
11. Tighten fuel line fitting to 27 N•m (20 lbf ft). 1. Install FTV to the throttle body.
12. Fill the coolant reservoir. 2. Install the two bolts and torque to 9 N•m
(80 lbf in).
3. Connect fuel supply hose.
14. Start the vehicle and check the propane fuel sys-
tem for leaks at each serviced fitting. Refer to 4. Connect FTV electrical connection.
5. Start the vehicle and check for leaks.

1. MIXER 13. THROTTLE BODY TO MANIFOLD ADAPTER
2. FITTING, 90 DEGREE 14. HEAT SHIELD
3. THROTTLE CABLE BRACKET 15. MANIFOLD GASKETS
4. BOLTS, THROTTLE BODY TO ADAPTER 16. O-RING
5. FITTING, BRASS VACUUM 17. BOLT, THROTTLE BODY TO ADAPTER
6. SCREWS, THROTTLE BODY TO MIXER 18. THROTTLE BODY
7. THROTTLE CABLE CONNECTION 19. VACUUM CAP
8. FOOT PEDAL POSITION (FPP) SENSOR 20. FUEL TRIM VALVE (FTV)
9. SCREWS 21. BOLTS
10. BOLT, ADAPTER TO MANIFOLD 22. THROTTLE POSITION SENSOR (TPS)
11. TEMPERATURE MANIFOLD ABSOLUTE 23. GOVERNOR MOTOR
PRESSURE (TMAP) SENSOR 24. MIXER INLET FITTING
12. SCREWS 25. PIN
26
Figure 22. 3.0L Mixer and Throttle Body Assembly
27
Figure 23. 4.3L Mixer and Throttle Body Assembly
28

1. MIXER 13. TEMPERATURE MANIFOLD ABSOLUTE
2. BOLTS, THROTTLE BODY TO ADAPTER PRESSURE (TMAP) SENSOR
3. THROTTLE CABLE BRACKET 14. BOLTS, ADAPTER TO MANIFOLD
4. THROTTLE CABLE CONNECTION 15. O-RING
5. FOOT PEDAL POSITION (FPP) SENSOR 16. BOLTS, THROTTLE BODY TO ADAPTER
6. SCREWS 17. THROTTLE BODY
7. LOW PRESSURE REGULATOR (LPR) 18. FUEL TRIM VALVE (FTV)
MOUNTING BRACKET 19. BOLTS
8. BOLTS, LPR MOUNTING BOLTS 20. THROTTLE POSITION SENSOR (TPS)
9. VACUUM FITTING 21. GOVERNOR MOTOR
10. MANIFOLD GASKET 22. SCREWS, THROTTLE BODY TO MIXER
11. THROTTLE BODY TO MANIFOLD ADAPTER 23. MIXER INLET FITTING
12. SCREWS 24. PIN
TEMPERATURE MANIFOLD ABSOLUTE Do not attempt to make any adjustments to the

PRESSURE (TMAP) sealed adjustment screw. If adjustments are
required, they can be made only by a qualified
Remove fuel injection shop that will ensure the injec-
tion pump continues to meet all applicable
See Figure 22 for the 3.0L, Figure 23 for the 4.3L, for emissions regulations and then replace the
the following steps: tamper-proof seal.
1. Disconnect the TMAP electrical connector. See Figure 22 for the 3.0L, Figure 23 for the 4.3L, for
the following steps:
2. Remove two retaining screws.
3. Remove the TMAP.
2. Remove the air intake duct.
Install
3. Disconnect the throttle cable.
the following steps: 4. Disconnect the FPP and TPS electrical connec-
tors.
NOTE: Apply a small amount of O-ring lubricant to
the TMAP O-ring before installation. 5. Disconnect the governor control device electrical
connector.
1. Install the TMAP.
6. Disconnect the FTV electrical connector.
2. Secure using the two retaining screws and torque
to 7 N•m (62 lbf in). 7. Disconnect the FTV supply line.
3. Connect the TMAP electrical connection. 8. Disconnect the PTV vacuum line.
4. Start engine and check for leaks. 9. Disconnect the balance line to the LPR.
THROTTLE BODY REPLACEMENT 10. Remove mixer fuel inlet hose clamp and remove
hose from mixer inlet.
Remove
11. Remove the four manifold to adapter bolts from
the throttle body adapter.
CAUTION
Do not attempt to remove, or adjust, the tam- 12. Lift assembly from the adapter and cover the
per-proof device (plug) from the sealed idle throttle body opening with a clean cloth.
screw on the throttle body assembly. These
13. Remove and discard the adapter O-ring.
adjustments have been made at the factory to
meet all applicable emissions regulations and 14. Remove the four throttle body to mixer screws.
then sealed.
29
15. Remove throttle body assembly. MIXER REPLACEMENT

NOTE: Cover throttle body adapter opening to pre- Remove
vent debris from entering engine until assembly.
16. Remove O-ring and discard. the following steps:
Install 1. Disconnect the negative battery cable.
See Figure 22 for the 3.0L, Figure 23 for the 4.3L, for 2. Remove the air intake duct.
the following steps:
3. Remove the throttle body assembly. Refer to
NOTE: Lightly lubricate both the O-rings of the throt- Throttle Body Replacement, Remove.
tle control device to adapter.
NOTE: Cover throttle body adapter opening to pre-
1. Install O-ring to the top of the throttle body as- vent debris from entering engine until assembly.
sembly.
4. Remove the four screws to the throttle body as-
2. Install throttle body onto the bottom of the mixer. sembly to mixer.
3. Tighten the four screws to 9 N•m (80 lbf in). 5. Remove and discard the mixer to throttle body
assembly O-ring.
4. Install throttle adapter O-ring.
Install
5. Install the throttle body onto the manifold
adapter. Line up the throttle cable bracket and See Figure 22 for the 3.0L, Figure 23 for the 4.3L, for
install four retaining bolts and torque to 12 N•m the following steps:
(106 lbf in).
NOTE: Lightly lubricate the O-ring of the mixer to
6. Connect the balance line to the LPR. throttle body O-ring before installing.
7. Connect the PTV vacuum line. 1. Install mixer to throttle body O-ring onto the
throttle body.
8. Connect the fuel supply line to the FTV.
2. Install the mixer to the throttle body assembly
9. Connect the fuel supply line to the mixer and se-
and secure with the four screws and torque to
cure clamp.
9 N•m (80 lbf in).
10. Connect the FTV electrical connector.
3. Install throttle body. Refer to Throttle Body Re-
11. Connect the governor electrical connector. placement, Install.
12. Connect the FPP and TPS electrical connectors. 4. Connect the negative battery cable.
13. Connect the throttle cable. COOLANT HOSE REPLACEMENT

14. Connect the air inlet duct. Remove
15. Connect the negative battery cable. 1. Drain coolant.
16. Start the vehicle and check the propane fuel sys- 2. Using hose clamp pliers, disconnect both hose
tem for leaks at each serviced fitting. Refer to clamps on each hose.
3. Remove the coolant inlet hose from each fitting.
17. Connect the laptop computer and check for DTC
codes and no MIL light. See the section Elec- 4. Remove the coolant outlet hose.
tronic Control Module (ECM) Diagnostic
Troubleshooting, GM 3.0L and 4.3L EPA
Compliant Engines 2200 SRM 1090.
30
Install 4. Remove hose routing retaining bolt.
5. Remove clamp at the LPR connection.

CAUTION
Coolant hoses are specifically designed. DO Install
NOT use any hose material. Only use HYSTER
approved parts.
CAUTION
Balance line hoses are specifically designed.
CAUTION DO NOT use any hose material. Only use HYS-
DO NOT mix the inlet or outlet hoses when in- TER approved parts.
stalling.
1. Install hose clamps and set back on each hose. CAUTION

DO NOT mix the hoses when installing.
2. Install the coolant inlet hose to each fitting.
3. Install the coolant outlet hose to each fitting. CAUTION

Install check valve in correct direction (arrow
4. Reset clamps. on check valve pointing away from mixer).
5. Fill with coolant. 1. Install hose clamps and set back on each hose.
6. Start engine and check for coolant leaks. 2. Install the LPR hose end to the LPR fitting and
set clamp.
VAPOR HOSE REPLACEMENT
3. Install check valve with the arrow pointing away
Remove from mixer and set clamp.
1. Using hose clamp pliers, disconnect both hose 4. Install the small hose section and set clamps.
clamps.
5. Start engine and check for leaks.
2. Remove the vapor hose from each fitting.
PTV HOSE REPLACEMENT
Install
Remove
CAUTION
1. Using hose clamp pliers, disconnect the clamps
Vapor supply hose is specifically designed. DO on the hose fitting at the mixer.
NOT use any hose material. Only use HYSTER
approved parts. 2. Using a small screwdriver, push the locking clip
back on PTV connection.
1. Install hose clamps and set back on each hose.
3. Remove the hose and discard.
2. Install the vapor hose to each fitting.
3. Reset clamps. Install
4. Start engine and check for leaks. CAUTION

PTV hoses are specifically designed. DO NOT
BALANCE LINE HOSE REPLACEMENT use any hose material. Only use HYSTER ap-
proved parts.
Remove
1. Install hose clamps and set back on the mixer
1. Remove the clamp to the fitting at the mixer.
hose end.
2. Remove small hose to check valve.
2. Install hose at the PTV and push lock in place.
3. Remove check valve.
3. Install hose at the mixer and set clamp.
31
4. Start engine and check for leaks. THROTTLE POSITION SENSOR (TPS)
REPLACEMENT
FTV HOSE REPLACEMENT
Refer to Figure 24 and Table 1 for the replacement
Remove procedures of the TPS.
1. Using a small screwdriver, push locking clips

back on FTV connection at FTV and LPR.
2. Remove the hose and discard.
Install
CAUTION
FTV hoses are specifically designed. DO NOT
use any hose material. Only use HYSTER ap-
proved parts.
1. Install hose at the FTV and LPR and push locks

in place. 1. TPS 2. SCREW
2. Start engine and check for leaks. Figure 24. Throttle Position Sensor (TPS)
Table 1. TPS Replacement Procedure
Step Action Value(s) Yes No

1 Were you instructed to replace the TPS from a Go to step 2. Go to
DTC. On-Board Di-
agnostics Sys-
tem Check
in the sec-
tion Elec-
tronic Con-
trol Module
(ECM) Diag-
nostic Trou-
bleshooting,
GM 3.0L and
4.3L EPA
Compliant
Engines 2200
SRM 1090.
2 • Key OFF. Go to step 3.
• Disconnect the negative battery cable and the
throttle body governor motor connector.
Are they disconnected?
32
Table 1. TPS Replacement Procedure (Continued)

3 • Disconnect the TPS wire harness connector and Go to step 4.
remove the two mounting screws using a 3mm
hex tool.
Is the wiring harness disconnected and the

mounting screws removed?
4 • Replace the TPS sensor and install the two Go to step 5.
mounting screws so that they just touch the
TPS sensor body.
Is the new TPS sensor installed with the

mounting screws still slightly loose?
5 • Reconnect the battery negative cable and the Go to step 6.
TPS wire harness connector. Leave the gover-
nor motor disconnected for now.
Has the negative battery cable and TPS wire

harness connector been reconnected?
6 • Connect the laptop computer and turn the igni- Go to step 7. Go to Diag-
tion key to the ON position. nostic Com-
munication
Is the laptop computer connected with the key in Error in the
the ON position? section Elec-
tronic Con-
trol Module
(ECM) Diag-
nostic Trou-
bleshooting,
GM 3.0L and
4.3L EPA
Compliant
Engines 2200
SRM 1090.
7 • With the throttle in the idle position, move the 3.460 to 3.534 Go to step 8. Replace
TPS sensor body while monitoring the laptop volts the throttle
computer raw volts screen for TPS 1 volts. 2.25 N•m assembly.
Set the TPS voltage between 3.460 to 3.534 (20 lbf in)
volts while tightening the two mounting screws
evenly to a maximum 2.25 N•m (20 lbf in).
Were you able to set the voltage between 3.460

to 3.534 volts with the mounting bolts torque set
to 2.25 N•m (20 lbf in)?
33

8 • Manually actuate the throttle to the wide open 0.484 to 0.645 Go to step 9. Replace
position and check that the voltage is between volts the throttle
0.484 to 0.645 volts. assembly.
Is the voltage between 0.484 to 0.645 volts?

9 • Turn the ignition key to the OFF position. Go to step 10.
• Connect the governor motor wire harness con-
nector.
Is the governor motor wire harness connector

connected?
10 • Remove all test equipment except the laptop System OK. Go to
computer. On-Board Di-
• Connect any disconnected components, fuses, agnostics Sys-
etc. tem Check
• Using the laptop computer, clear DTC informa- in the sec-
tion from the ECM. tion Elec-
• Turn the ignition OFF and wait 30 seconds. tronic Con-
• Start the engine and operate the vehicle to full trol Module
operating temperature. (ECM) Diag-
• Observe the MIL. nostic Trou-
• Observe engine performance and driveablility. bleshooting,
GM 3.0L and
Does the engine operate normally with no stored 4.3L EPA
codes? Compliant
Engines 2200
SRM 1090.
FOOT PEDAL POSITION (FPP) SENSOR

REPLACEMENT
procedures of the FPP.
1. FPP 2. SCREW
Figure 25. Foot Pedal Position (FPP) Sensor
34
Table 2. FPP Replacement Procedure

1 Were you instructed to replace the FPP from a Go to step 2. Go to
DTC. On-Board Di-
agnostics Sys-
tem Check
in the sec-
tion Elec-
tronic Con-
trol Module
(ECM) Diag-
nostic Trou-
bleshooting,
GM 3.0L and
4.3L EPA
Compliant
Engines 2200
SRM 1090.

3 • Disconnect the FPP wire harness connector and Go to step 4.
hex tool.

4 • Replace the FPP sensor and install the two Go to step 5.
FPP sensor body.
Is the new FPP sensor installed with the

FPP wire harness connector. Leave the gover-
Has the negative battery cable and FPP wire

35
Table 2. FPP Replacement Procedure (Continued)

munication
tronic Con-
trol Module
(ECM) Diag-
nostic Trou-
bleshooting,
GM 3.0L and
4.3L EPA
Compliant
Engines 2200
SRM 1090.
FPP sensor body while monitoring the laptop volts the throttle
computer raw volts screen for FPP 1 volts. 2.25 N•m assembly.
Set the FPP voltage between 1.408 to 1.510 (20 lbf in)

to 2.25 N•m (20 lbf in)?
36

nector.

connected?
etc. tem Check
GM 3.0L and
codes? Compliant
Engines 2200
SRM 1090.
ELECTRONIC CONTROL MODULE (ECM) 1. Plug connector into ECM.

REPLACEMENT
2. Push lock into place.
Remove 3. Mount ECM into mounting bracket.
1. Disconnect negative battery cable. 4. Connect the battery cable.
2. Remove ECM from mounting bracket. 5. Connect the laptop computer. See the section
3. Push connector lock back to unlock connector. Electronic Control Module (ECM) Diagnos-
tic Troubleshooting, GM 3.0L and 4.3L EPA
4. Unplug ECM and remove. Compliant Engines 2200 SRM 1090.
Install 6. Start engine.
7. Check for any DTC codes and clear them.

CAUTION
The ECM is calibrated for each engine. Verify 8. Verify engine is in closed loop and no MIL lights
you have the correct ECM. are present.
37
HEATED EXHAUST GAS OXYGEN (HEGO) RESTRICTED EXHAUST SYSTEM

SENSOR REPLACEMENT DIAGNOSIS
Remove Exhaust System Description
1. Disconnect negative battery cable. The emission certified engine has been designed and
calibrated to meet the emission standards in effect
2. Disconnect the O 2 sensor electrical connector. for 2004. To help meet the emission requirements,
the vehicle has been equipped with a Three-Way Cat-
3. Using a O 2 sensor socket, remove the O 2 sensor
alytic (TWC) muffler. The catalyst muffler is a three-
and discard.
way catalyst, sound damping, and spark arresting
unit. Besides controlling the noise created from the
Install
combustion process and preventing sparks from es-
NOTE: Before installing the O 2 sensor, lubricate caping from the exhaust system, the most important
threads with antiseize compound. Avoid getting function is treating the exhaust gases which are cre-
compound on the sensor tip. ated from the combustion process.
1. Install O 2 sensor and torque to 41 N•m (30 lbf ft). The three-way catalyst consists of a honeycomb,
coated with a mixture of platinum, palladium, and
2. Start engine. rhodium. The hot gases flow through the catalyst
sections where an oxidation and reduction reactions
3. Check for any DTC codes and clear. take place. These chemical reactions reduce the
amount of carbon monoxide (CO), hydrocarbon (HC),
4. Verify engine is in closed loop and no MIL lights
and nitrogen oxide (NOx) in the engine’s exhaust.
are present.
The exhaust gas then flows through the outlet.
THREE-WAY CATALYTIC MUFFLER (TWC) During normal operation, the exhaust system could
REPLACEMENT become damaged. Damage, which reduces the flow of
the exhaust gas, will create increased back pressure
Remove in the engine. Reduction in exhaust flow can result
from crushed muffler outlets or melted catalyst brick
1. Remove the TWC muffler. Refer to the Frame
inside the converter.
section of your lift truck.
It may be necessary to measure the back pressure in
Install the exhaust system. To determine if the back pres-
sure in the engine is correct, use the following proce-
CAUTION dure:
The three-way catalytic muffler is specifically
Tools Required
designed to meet the emission control of the
certified engine. Use only the HYSTER ap- • Exhaust back pressure gauge
proved parts.
Diagnostic Tool
1. Install the TWC muffler. Refer to the Frame
section of your lift truck. • Laptop Computer (see the section Electronic
Control Module (ECM) Diagnostic Trou-
2. Start engine. bleshooting, GM 3.0L and 4.3L EPA Compli-
ant Engines 2200 SRM 1090).
3. Check for any DTC codes and clear.

are present.
38
900 SRM 1088 Gasoline Fuel System Repair
Check at Heated Exhaust Gas Oxygen

Sensor (HEGO)
1. Carefully remove the HEGO. Refer to Heated Ex-
haust Gas Oxygen (HEGO) Sensor Replacement,
Remove.
2. Install exhaust back pressure test gauge in place

of the HEGO. See Figure 26.
3. With the engine idling at normal operating tem-

perature, observe the exhaust system back pres-
sure reading on the gauge. Reading should not
exceed 8.6 kPa (1.25 psi).
4. Increase engine speed to 2000 rpm and observe

gauge. Reading should not exceed 20.7 kPa
(3 psi).
5. If the back pressure at either speed exceeds

specification, a restricted exhaust system is in-
dicated.
6. Inspect the entire exhaust system for a collapsed

pipe, heat distress, or possible internal muffler
failure.
1. BACK PRESSURE GAUGE
7. If there are no obvious reasons for the exces- 2. OXYGEN SENSOR (O 2S)
3. EXHAUST MANIFOLD
sive back pressure, the catalytic converter is sus-
pected to be restricted and should be replaced us- Figure 26. Exhaust Back Pressure Gauge
ing current recommended procedures.
Gasoline Fuel System Repair

GASOLINE MPFI AND TBI FUEL SYSTEM WARNING
PRESSURE RELIEF Residual vapor pressure will be present in the
fuel system. Ensure the work area is well ven-
WARNING tilated before disconnecting any fuel line.
The fuel system operates at pressures up to
1. Disconnect the electrical connector at the fuel
405 kPa (60 psi). To minimize the risk of fire
pump.
and personal injury, relieve the gasoline fuel
system pressure (where applicable) before ser- 2. Start and run the vehicle until the engine stalls.
vicing the gasoline fuel system components.
3. Turn the ignition switch OFF.
WARNING 4. Remove the cap on the gasoline pressure test
Keep open flame away from any open fuel line port.
to minimize the risk of fire and personal injury.
5. Wrap a shop towel around the fitting and using a
small screwdriver depress valve and insure there
is no pressure left in the system.
39
Gasoline Fuel System Repair 900 SRM 1088
GASOLINE FUEL SYSTEM LEAK TEST NOTE: Cover throttle body adapter opening to pre-
WARNING 10. Remove and discard the O-ring.
Never use an open flame of any type to check
for gasoline fuel system leaks. Install
Always inspect the gasoline fuel system for leaks af- See Figure 27 for the following steps:
ter performing service. Check for leaks at the fittings
of the serviced or replaced component. NOTE: Lightly lubricate both O-rings of the throttle
control device to TBI assembly.
THROTTLE BODY INJECTOR (TBI)
ASSEMBLY REPLACEMENT, 3.0L ONLY 1. Install the O-ring into the throttle body assem-
bly.
Remove 2. Install the TBI assembly.
See Figure 27 for the following steps: 3. Install the TBI assembly with the four bolts and
1. Disconnect the negative battery cable. torque to 12 N•m (106 lbf in).
2. Relieve the gasoline fuel system pressure. Refer 4. Install the air inlet adapter to the TBI assembly
to Gasoline MPFI and TBI Fuel System Pressure and torque to 9 N•m (80 lbf in).
Relief. 5. Connect the injector electrical connector.
3. Disconnect the fuel pump electrical connector. 6. Connect the fuel supply line to the TBI assembly
4. Remove the air intake duct. and torque to 27 N•m (20 lbf ft).
5. Remove the four screws from the air intake 7. Connect the fuel return line to the TBI assembly
adapter to the TBI and the air intake hose and torque to 27 N•m (20 lbf ft).
adapter. 8. Connect the fuel pump electrical connector.
6. Disconnect the fuel inlet line. 9. Connect the negative battery cable.
7. Disconnect the fuel return line. 10. Start engine and check for leaks.
8. Disconnect the injector electrical connector. 11. Connect the laptop computer and check for
9. Remove the four TBI assembly to throttle body DTC codes or MIL lights. See the section Elec-
assembly bolts from the throttle body injector as- tronic Control Module (ECM) Diagnostic
sembly and remove the electronic TBI assembly. Troubleshooting, GM 3.0L and 4.3L EPA

1. TBI INJECTOR ASSEMBLY 14. BOLT
2. CLIP 15. SCREWS
3. O-RING 16. TEMPERATURE MANIFOLD ABSOLUTE
4. FUEL INJECTOR PRESSURE (TMAP) SENSOR
5. SCREW 17. GASKETS
6. SCREWS 18. HEAT SHIELD
7. AIR INTAKE HOSE ADAPTER 19. THROTTLE BODY TO MANIFOLD ADAPTER
8. GASKET 20. O-RING
9. BOLTS 21. THROTTLE BODY
10. THROTTLE CABLE BRACKET 22. BOLT
11. THROTTLE CABLE CONNECTION 23. THROTTLE POSITION SENSOR (TPS)
12. FOOT PEDAL POSITION (FPP) SENSOR 24. GOVERNOR MOTOR
13. SCREWS
40
Figure 27. Throttle Body Assembly, 3.0L Only
41
THROTTLE BODY ASSEMBLY 1. Install the O-ring to the throttle body assembly
REPLACEMENT, 3.0L ONLY to manifold adapter.
Remove 2. Install the throttle body assembly to the adapter.
3. Place the throttle cable bracket and secure using

CAUTION the four bolts and torque to 12 N•m (106 lbf in).
Do not attempt to remove, or adjust, the tam-
per-proof device (plug) from the sealed idle 4. Connect the governor motor electrical connec-
screw on the throttle body assembly. These tion.
adjustments have been made at the factory to 5. Connect the FPP and TPS electrical connections.
meet all applicable emissions regulations and
then sealed. 6. Install the TBI assembly. Refer to Throttle Body
Injector (TBI) Assembly Replacement, 3.0L Only,
Do not attempt to make any adjustments to the Install.
sealed adjustment screw. If adjustments are
required, they can be made only by a qualified 7. Start engine and check for leaks.
fuel injection shop that will ensure the injec-
tion pump continues to meet all applicable 8. Connect the laptop computer and check for
emissions regulations and then replace the DTC codes or MIL lights. See the section Elec-
tamper-proof seal. tronic Control Module (ECM) Diagnostic
See Figure 27 for the following steps: Compliant Engines 2200 SRM 1090.
1. Remove the TBI assembly. Refer to Throttle THROTTLE BODY ASSEMBLY

Body Injector (TBI) Assembly Replacement,
REPLACEMENT, 4.3L ONLY
3.0L Only, Remove.
2. Disconnect the FPP and TPS electrical connec- Remove

tions.
CAUTION
3. Disconnect the governor motor electrical connec-
Do not attempt to remove, or adjust, the tam-
tion.
per-proof device (plug) from the sealed idle
4. Disconnect the throttle cable. screw on the throttle body assembly. These
adjustments have been made at the factory to
5. Remove the four throttle body assembly to man- meet all applicable emissions regulations and
ifold adapter bolts. then sealed.
NOTE: Cover throttle body adapter opening to pre- Do not attempt to make any adjustments to the
vent debris from entering engine until assembly. sealed adjustment screw. If adjustments are
required, they can be made only by a qualified
6. Remove and discard the O-ring seal. fuel injection shop that will ensure the injec-
tion pump continues to meet all applicable
Install emissions regulations and then replace the
tamper-proof seal.
NOTE: Lightly lubricate both the O-rings of the throt-
tle control device to TBI assembly.
42
6. From the bottom of the throttle body assembly,

remove the four bonnet screws and remove the
bonnet.
7. Remove the O-ring and discard.
8. Remove the four throttle body assembly to man-

ifold bolts from the throttle body assembly and
remove the throttle body assembly.
NOTE: Cover throttle body adapter opening to pre-

9. Remove the throttle body O-ring and discard.
Install
NOTE: Lightly lubricate both the O-rings of the throt-

1. Install the O-ring into the throttle body assem-

bly.
1. SCREWS 2. Install the bonnet to the throttle body assembly

2. AIR INTAKE HOSE ADAPTER and secure with the four screws and torque to
3. GASKET 9 N•m (80 lbf in).
4. BONNET
5. O-RING 3. Secure the throttle body assembly to the man-
6. SCREWS ifold adapter with the four bolts and torque to
7. CAPSCREW 12 N•m (106 lbf in).
9. THROTTLE CABLE BRACKET
10. THROTTLE BODY TO MANIFOLD ADAPTER 4. Connect the FPP and TPS electrical connections.
11. THROTTLE BODY
12. CAPSCREWS 5. Connect governor motor electrical connector.
6. Connect the throttle cable.
Figure 28. Throttle Body Assembly, 4.3L Only
7. Connect the air inlet duct.
2. Remove the air intake duct.
9. Start engine.
3. Disconnect the FPP and TPS electrical connec-
tions. 10. Connect the laptop computer and check for
DTC codes or MIL lights. See the section Elec-
4. Disconnect the governor motor electrical connec- tronic Control Module (ECM) Diagnostic
tion. Troubleshooting, GM 3.0L and 4.3L EPA
5. Disconnect the throttle cable.
43
1. FUEL PRESSURE TEST PORT 7. MANIFOLD ASSEMBLY

2. FUEL PRESSURE REGULATOR HOSE 8. INJECTOR SHIELDS
3. PRESSURE REGULATOR RETAINER CLIP 9. BOLTS, THROTTLE BODY FRONT
4. PRESSURE REGULATOR 10. BOLT, THROTTLE BODY REAR
5. TEMPERATURE MANIFOLD ABSOLUTE 11. BOLT
PRESSURE (TMAP) SENSOR 12. FUEL INJECTOR RETAINER CLIPS
6. INJECTORS 13. FUEL RAIL ASSEMBLY
Figure 29. Injector Fuel Rail and Manifold
44
FUEL RAIL REPLACEMENT, GASOLINE 8. Install the air duct.

4.3L ONLY
Remove 10. Start engine and check for leaks.
See Figure 29 for the following steps: 11. Connect the laptop computer and check for
1. Disconnect the negative battery cable. DTC codes or MIL lights. See the section Elec-
2. Disconnect the air duct. Troubleshooting, GM 3.0L and 4.3L EPA
3. Remove the throttle body assembly. Refer to
Throttle Body Assembly Replacement, 4.3L INJECTOR REPLACEMENT, GASOLINE
Only, Remove. 4.3L ONLY
4. Disconnect the fuel supply line to the rail assem-
Remove
bly.
5. Disconnect the fuel return line to the rail assem-
bly. 1. Disconnect the negative battery cable.
6. Disconnect the vacuum line to the pressure reg- 2. Relieve the fuel system pressure. Refer to Gaso-
ulator. line MPFI and TBI Fuel System Pressure Relief.
7. Remove the four fuel rail bolts to the manifold. 3. Remove the fuel rail assembly. Refer to Fuel Rail
Replacement, Gasoline 4.3L Only, Remove.
8. With a screwdriver, press back on the six injector
retaining clips and remove. 4. Disconnect the six injector electrical connections.
NOTE: Cover throttle body adapter opening to pre- 5. Remove each injector.
Install
9. Carefully lift the fuel rail off the injectors.
Install
NOTE: Apply a small amount of O-ring lubricant to
See Figure 29 for the following steps: the injector O-rings before installation.
NOTE: Lightly lubricate both the O-rings of the throt- 1. Install the injectors.
2. Connect the injector electrical connectors.
1. Carefully place the fuel rail over all the injector
and press down to set the rails. 3. Install the fuel rail assembly. Refer to Fuel Rail
Replacement, Gasoline 4.3L Only, Install.
2. Install the six injector retaining clips.
3. Secure the fuel rail to the manifold with the four
retaining bolts and torque to 12 N•m (106 lbf in). 5. Connect the laptop computer and check for
4. Connect the vacuum line to the pressure regula- tronic Control Module (ECM) Diagnostic
tor. Troubleshooting, GM 3.0L and 4.3L EPA
5. Connect the fuel return line.
6. Connect the fuel supply line.
7. Install the throttle body assembly. Refer to

Throttle Body Assembly Replacement, 4.3L
Only, Install.
45
INJECTOR REPLACEMENT, GASOLINE Install

3.0L ONLY
NOTE: Apply a small amount of lubricant to the
Remove TMAP O-ring.
See Figure 27 for the following steps: 1. Install TMAP.
1. Relieve the fuel system pressure. Refer to Gaso- 2. For the 3.0L, secure using the two retaining
line MPFI and TBI Fuel System Pressure Relief. screws and torque to 6 N•m (54 lbf in).
2. Disconnect the injector electrical connection. 3. For the 4.3L, secure using the retaining bolt and
torque to 6 N•m (54 lbf in).
3. Remove the injector retaining screw.
4. Connect the TMAP electrical connector.
4. Remove the injector.
5. Start engine.
Install 6. Connect the laptop computer and check for
See Figure 27 for the following steps: DTC codes or MIL lights. See the section Elec-
NOTE: Apply a small amount of O-ring lubricant to Troubleshooting, GM 3.0L and 4.3L EPA
the injector O-rings before installation. Compliant Engines 2200 SRM 1090.
1. Install the injector. THROTTLE POSITION SENSOR (TPS)

2. Secure the injector using the retaining screw and
REPLACEMENT
torque to 2 to 2.4 N•m (18 to 21 lbf in). Refer to Figure 30 and Table 3 for the replacement
procedures of the TPS.
3. Connect the injector electrical wire connector.
5. Connect the laptop computer and check for

TEMPERATURE MANIFOLD ABSOLUTE

PRESSURE (TMAP) REPLACEMENT
Remove
1. Disconnect the TMAP electrical connection. 1. TPS 2. SCREW
2. For the 3.0L, remove two retaining screws and Figure 30. Throttle Position Sensor (TPS)
remove the TMAP.
3. For the 4.3L, remove the retaining bolt and re-

move the TMAP.
46
Table 3. TPS Replacement Procedure

1 Were you instructed to replace the TPS from a Go to step 2. Go to
DTC? On-Board Di-
agnostics Sys-
tem Check
in the sec-
tion Elec-
tronic Con-
trol Module
(ECM) Diag-
nostic Trou-
bleshooting,
GM 3.0L and
4.3L EPA
Compliant
Engines 2200
SRM 1090.

3 • Disconnect the TPS wire harness connector and Go to step 4.
hex tool.

4 • Replace the TPS sensor and install the two Go to step 5.
TPS sensor body.
Is the new TPS sensor installed with the

TPS wire harness connector. Leave the gover-
Has the negative battery cable and TPS wire

47

munication
tronic Con-
trol Module
(ECM) Diag-
nostic Trou-
bleshooting,
GM 3.0L and
4.3L EPA
Compliant
Engines 2200
SRM 1090.
TPS sensor body while monitoring the laptop volts the throttle
computer raw volts screen for TPS 1 volts. 2.25 N•m assembly.
Set the TPS voltage between 3.460 to 3.534 (20 lbf in)

to 2.25 N•m (20 lbf in)?
48

nector.

connected?
etc. tem Check
GM 3.0L and
codes? Compliant
Engines 2200
SRM 1090.
FOOT PEDAL POSITION (FPP) SENSOR

REPLACEMENT
procedures of the FPP.
1. FPP 2. SCREW
Figure 31. Foot Pedal Position (FPP) Sensor
49
Table 4. FPP Replacement Procedure

1 Were you instructed to replace the FPP from a Go to step 2. Go to
DTC. On-Board Di-
agnostics Sys-
tem Check
in the sec-
tion Elec-
tronic Con-
trol Module
(ECM) Diag-
nostic Trou-
bleshooting,
GM 3.0L and
4.3L EPA
Compliant
Engines 2200
SRM 1090.

3 • Disconnect the FPP wire harness connector and Go to step 4.
hex tool.

4 • Replace the FPP sensor and install the two Go to step 5.
FPP sensor body.
Is the new FPP sensor installed with the

FPP wire harness connector. Leave the gover-
Has the negative battery cable and FPP wire

50

munication
tronic Con-
trol Module
(ECM) Diag-
nostic Trou-
bleshooting,
GM 3.0L and
4.3L EPA
Compliant
Engines 2200
SRM 1090.
FPP sensor body while monitoring the laptop volts the throttle
computer raw volts screen for FPP 1 volts. 2.25 N•m assembly.
Set the FPP voltage between 1.408 to 1.510 (20 lbf in)

to 2.25 N•m (20 lbf in)?
51

nector.

connected?
etc. tem Check
GM 3.0L and
codes? Compliant
Engines 2200
SRM 1090.
ELECTRONIC CONTROL MODULE (ECM) 5. Connect the laptop computer and check for
REPLACEMENT DTC codes or MIL lights. See the section Elec-
Remove Troubleshooting, GM 3.0L and 4.3L EPA
1. Disconnect negative battery cable.
6. Start engine.
2. Remove ECM from mounting bracket.
7. Check for any DTC codes and clear them.
3. Push connector lock back to unlock connector.
4. Unplug ECM and remove. are present.
Install HEATED EXHAUST GAS OXYGEN (HEGO)

SENSOR REPLACEMENT
CAUTION
The ECM is calibrated for each engine. Verify Remove
you have the correct ECM.
1. Disconnect negative battery cable.
1. Plug connector into ECM.
2. Disconnect the O 2 sensor electrical connector.
2. Push lock into place.
3. Using a O 2 sensor socket, remove the O 2 sensor
3. Mount ECM into mounting bracket. and discard.
4. Connect the battery cable.
52
Install function is treating the exhaust gases which are cre-

ated from the combustion process.
NOTE: Before installing the O 2 sensor, lubricate
threads with antiseize compound. Avoid getting The three-way catalyst consists of a honeycomb,
compound on the sensor tip. coated with a mixture of platinum, palladium, and
rhodium. The hot gases flow through the catalyst
1. Install O 2 sensor and torque to 41 N•m (30 lbf ft). sections where an oxidation and reduction reactions
take place. These chemical reactions reduce the
2. Start engine.
amount of carbon monoxide (CO), hydrocarbon (HC),
3. Check for any DTC codes and clear. and nitrogen oxide (NOx) in the engine’s exhaust.
The exhaust gas then flows through the outlet.
are present. During normal operation, the exhaust system could
become damaged. Damage, which reduces the flow of
THREE-WAY CATALYTIC MUFFLER (TWC) the exhaust gas, will create increased back pressure
REPLACEMENT in the engine. Reduction in exhaust flow can result
from crushed muffler outlets or melted catalyst brick
Remove inside the converter.
1. Remove the TWC muffler. Refer to the Frame It may be necessary to measure the back pressure in
section of your lift truck. the exhaust system. To determine if the back pres-
sure in the engine is correct, use the following proce-
Install dure:
Tools Required
CAUTION
The three-way catalytic muffler is specifically • Exhaust back pressure gauge
designed to meet the emission control of the
Diagnostic Tool
certified engine. Use only the HYSTER ap-
proved parts. • Laptop Computer (see the section Electronic
Control Module (ECM) Diagnostic Trou-
1. Install the TWC muffler. Refer to the Frame
bleshooting, GM 3.0L and 4.3L EPA Compli-
section of your lift truck.
ant Engines 2200 SRM 1090).
2. Start engine.
Check at Heated Exhaust Gas Oxygen
3. Check for any DTC codes and clear. Sensor (HEGO)
4. Verify engine is in closed loop and no MIL lights 1. Carefully remove the HEGO. Refer to Heated Ex-
are present. haust Gas Oxygen (HEGO) Sensor Replacement,
Remove.
RESTRICTED EXHAUST SYSTEM
DIAGNOSIS 2. Install exhaust back pressure test gauge in place
of the HEGO. See Figure 32.
Exhaust System Description 3. With the engine idling at normal operating tem-
The emission certified engine has been designed and perature, observe the exhaust system back pres-
calibrated to meet the emission standards in effect sure reading on the gauge. Reading should not
for 2004. To help meet the emission requirements, exceed 8.6 kPa (1.25 psi).
the vehicle has been equipped with a Three-Way Cat-
4. Increase engine speed to 2000 rpm and observe
alytic (TWC) muffler. The catalyst muffler is a three-
gauge. Reading should not exceed 20.7 kPa
way catalyst, sound damping, and spark arresting
(3 psi).
unit. Besides controlling the noise created from the
combustion process and preventing sparks from es- 5. If the back pressure at either speed exceeds
caping from the exhaust system, the most important specification, a restricted exhaust system is in-
dicated.
53
LPG System Diagnosis 900 SRM 1088
6. Inspect the entire exhaust system for a collapsed

pipe, heat distress, or possible internal muffler
failure.
7. If there are no obvious reasons for the exces-

sive back pressure, the catalytic converter is sus-
pected to be restricted and should be replaced us-
ing current recommended procedures.
1. BACK PRESSURE GAUGE

2. OXYGEN SENSOR (O 2S)
3. EXHAUST MANIFOLD
Figure 32. Exhaust Back Pressure Gauge
LPG System Diagnosis

FUEL SYSTEM DESCRIPTION
The ECM receives information from various engine
sensors in order to control the operation of the FTV
and the LPL solenoid. The LPL solenoids prevent
fuel flow unless the engine is cranking or running.
LPG is stored in the tank and delivered under pres-
sure to the system as a liquid. During key ON, the
LPL receives a 2-second prime pulse from the ECM
which allows LPG to flow from the tank through fuel
filter and fuel lines to the LPR at pressures up to
21.5 kPa (312 psi). See Figure 33.
In the LPR, the fuel is vaporized and the pressure

is reduced in two stages. The first stage reduces
the pressure to approximately 13.8 to 27.6 kPa (2 to
4 psi). The second stage reduces the pressure to ap- 1. LPL
proximately negative 38.1 mm (1.5 in.) of water col- 2. PRESSURE TRIM VALVE
umn (WC). 3. PRIMARY TEST PORT
4. SECONDARY TEST PORT
Figure 33. Low Pressure Regulator Assembly
54
900 SRM 1088 LPG System Diagnosis
The fuel is then drawn from the secondary chamber Diagnostic Tool
of the LPR by the vacuum generated by air flowing
through the mixer. This vacuum signal is also used to • Laptop computer (see Electronic Control Mod-
generate lift for the mixer air valve. This vacuum sig- ule (ECM) Diagnostic Troubleshooting, GM
nal is most commonly referred to as air valve vacuum 3.0L and 4.3L EPA Compliant Engines 2200
(AVV). In the mixer, the fuel mixes with the air enter- SRM 1090).
ing the engine. This air/fuel mixture is then drawn
into the engine for combustion. Pressure Gauges
• Water column gauge/manometer (GM 7333-6 or
DIAGNOSTIC AIDS
equivalent).
This procedure is intended to diagnose a vehicle op- • 0-10 psi gauge
erating on LPG. If the vehicle will not continue to
run on LPG, refer to LPG Symptom Diagnosis, Hard Test Description
Start for preliminary checks. Before proceeding with
The steps listed below refer to step numbers in Ta-
this procedure, verify that the vehicle has a sufficient
ble 5:
quantity of fuel and that liquid fuel is being deliv-
• Step 5 will determine if the PTV and FTV and fuel
ered to the LPR. Also, ensure that the manual shut-
supply system are functioning properly. The vac-
off valve on the LPG tank is fully opened and that
uum on the secondary test port will be approxi-
the excess flow valve has not been activated.
mately –1.0 to –2.0 in. WC.
• Step 6 checks the base mechanical LPR output
Tools Required
pressure by disabling all fuel control devices.
• 7/16 open end wrench (for test port plugs) • Step 9 checks for proper air valve operation.
• Straight blade screwdriver • Step 19 determines if fuel is available from the fuel
• DVOM (GM J39200, Fluke 88 or equivalent) tank supply system.
Duty Cycle Monitoring Tool

• IMPCO fuel system analyzer (FSA), or DVOM (GM
J39200, Fluke 88 or equivalent)
Table 5. LPG Fuel System Diagnosis

1 Were you referred to this procedure by a DTC Go to Step 3 Go to Step 2
diagnostic chart?
2 Perform the on-board diagnostic (OBD) system Go to the Go to Step 3
check. Refer to Electronic Control Module applicable
(ECM) Diagnostic Troubleshooting, GM DTC table.
3.0L and 4.3L EPA Compliant Engines
2200 SRM 1090)Electronic Control Module
(ECM) Diagnostic Troubleshooting, GM 4.3L
Engines 2200 YRM 1219.
Are any DTCs present in the ECM?

3 Verify that the LPG fuel tank has a minimum of Go to Step 4 Add fuel.
1/4 tank of fuel, that the manual valve is open,
and the tank quick connect is fully engaged.
Does the vehicle have fuel?
55
Table 5. LPG Fuel System Diagnosis (Continued)

4 1. Connect a water column gauge or a manome- Go to Step 5 Go to Step 8
ter to the secondary test port of the LPR.
2. Start the engine and allow it to reach operat-
ing temperature.
Does the engine start and run?
5 With the engine idling, observe the pressure -1.0 to -2.0 Go to Step 25 Go to Step 6
reading for the LPR secondary pressure. in. WC
Does the fuel pressure fluctuate rhythmically

outside the specified range?
6 -1.0 to -2.0 Go to Table 6 Go to Step 7
NOTE: This action may cause a DTC to be set by in. WC
the ECM.
1. Disconnect the PTV electrical connector.

2. With the engine idling, observe the pressure
reading on the secondary test port.
Is the fuel pressure within the specified range?
7 1. Inspect the air intake stream between the Go to Step 26 Go to Step 22
mixer assembly and the throttle body for
leaks.
2. Inspect the fuel hose connection between the
LPR and mixer assembly for damage or leak-
age.
3. Inspect the vacuum hoses to the FTV solenoid.
Was a problem found and corrected?
8 1. Connect a water column gauge or a manome- Go to Step 12 Go to Step 9
ter to the secondary test port of the LPR.
2. Crank the engine and observe the pressure
reading for the LPR secondary pressure.
Does the fuel pressure indicate a vacuum is
present?
9 1. Remove air induction hose to the mixer. Go to Step 11 Go to Step 10
2. Observe the air valve for movement while the
engine is cranking.
NOTE: Movement of the air valve will be minimal

at cranking speeds.
Does the air valve move when the engine is

cranked?
10 1. Inspect the air intake stream to the mixer Go to Step 26 Go to Step 24
assembly and the throttle body for vacuum
leaks.
2. Inspect the vacuum hoses from the mixer to
the PTV solenoids for proper connection and
condition.
Was a problem found and repaired?
56

11 Inspect the fuel hose connection between the LPR Go to Step 26 Go to Step 12
and the mixer assembly for damage or leakage.
Was a problem found and repaired?

12 1. Connect a 0-10 psi gauge to the primary test 13.8 to Go to Step 22 Go to Step 13
port of the LPR. 27.6 kPa (2
2. Crank the engine and observe the pressure to 4 psi)
reading for the LPR primary pressure.
Is the fuel pressure above the specified value?
13 1. Turn OFF the ignition. Go to Step 14 Go to Step 16
2. Disconnect the LPL connector.
3. Install a test light between the pins of the LPL
connector.
4. Crank the engine. The test light should illu-
minate.
Does the test light illuminate?
14 Using a DVOM, check the resistance of the LPL. 12 to 24 Go to Step 15 Go to Step 23
Is the resistance within the specified range?

15 Go to Step 23 Go to Step 17
CAUTION
When disconnecting LPG fuel lines, liquid
LPG may be present. Perform this step in
a well-ventilated area.
1. Turn the ignition OFF.

2. Close the manual shutoff valve on the LPG
tank.
3. Loosen the fuel inlet hose fitting at the inlet
of the LPL.
Was fuel present when the fitting was loosened?
16 1. Turn OFF the ignition. Go to Step 20 Go to Step 21
2. Connect the test light to chassis ground and
probe pin A of the LPL connector.
3. Crank the engine. The test light should illu-
minate.
Does the test light illuminate?
57

17 1. Remove the LPG fuel filter/LPL. Go to Step 19 Go to Step 23
2. Remove the filter from the LPL.
3. Empty the contents of the inlet side of the LPG
fuel filter onto a clean surface.
4. Inspect the contents of the LPG fuel filter for
an excessive amount of foreign material or wa-
ter. If necessary, locate and repair the source
of contamination.
5. Verify the LPG fuel filter is not restricted or
plugged.
Was a problem found?
18 The fuel supply system or hoses are plugged or Go to Step 26
restricted, locate and repair the problem.
Is this action complete?

19 Replace the fuel filter. Refer to Propane Fuel Go to Step 26
Filter Replacement.

20 Repair the open in the lock-off ground circuit. Go to Step 26
Is the action complete?

21 Repair the open in the lock-off power circuit Go to Step 26

22 Replace the LPR. Refer Low Pressure Regulator. Go to Step 26

23 Replace the lock-off. Refer to Low Pressure Go to Step 26
Lock-Off (LPL) Replacement.

24 Replace the mixer assembly. Refer to Mixer Go to Step 26
Replacement.
58

25 The fuel supply system is operating normally, if System OK
a failure of the control solenoids is suspected.
Refer to Table 6.
1. Install the test plug in the LPR secondary
chamber.
2. If you were sent to this routine by another di-
agnostic chart, return to the previous diagnos-
tic procedure.
26 1. Disconnect all test equipment. System OK
2. Install the primary and secondary test port
plugs.
3. Start the engine.
4. Using an approved liquid leak detector, leak
check the test port plugs.
Table 6. Fuel Control Diagnosis

1 Were you referred to this procedure by another Go to Step 3 Go to Step 2
diagnostic chart?
2 Perform the On-Board Diagnostic (OBD) System Go to Go to Step 3
check. Refer to Electronic Control Module Applicable
(ECM) Diagnostic Troubleshooting, GM DTC Table
3.0L and 4.3L EPA Compliant Engines
2200 SRM 1090)Electronic Control Module
(ECM) Diagnostic Troubleshooting, GM
4.3L Engines 2200 YRM 1219.

3 Has the fuel system diagnosis been performed? Go to Step 4 Go to Table 5
59
Table 6. Fuel Control Diagnosis (Continued)

4 1. Connect the laptop computer. 20 to 80 Go to Step 6 Go to Step 5
2. Start the engine and allow it to reach operat- percent
ing temperature.
3. With the engine idling, observe the duty cycle
reading of the PTV on the laptop computer or
back probe the PTV connector. Connect a duty
cycle monitoring tool at the PTV connector as
follows:
• IMPCO FSA
– Yellow clip to pin A
– Green Clip (not used for this test)
– Red clip to 12V battery positive
– Black Clip to battery negative
• DVOM:
Back probe the PTV connector. Set the
DVOM for duty cycle percentage and con-
nect between pin A and battery negative
ground.
Is the PTV duty cycle within the specified range?
5 Is the PTV duty cycle above the specified value ? 80 percent Go to Step 7 Go to Step 6
6 1. Raise the engine speed to approximately 2500 20 to 80 Go to Step 7 Go to Step 9
rpm or greater. percent
2. Observe the duty cycle reading of the PTV.
Is the PTV duty cycle within the specified range?
7 1. Connect the laptop computer. 20 to 80 Go to Step 24 Go to Step 8
2. Start the engine and allow it to reach operat- percent
ing temperature.
3. With the engine idling, observe the duty cycle
reading of the FTV on the laptop computer or
back probe the FTV connector. Connect a duty
cycle monitoring tool at the FTV connector as
follows:
• IMPCO FSA
– Yellow clip to pin A
– Green Clip (not used for this test)
– Red clip to 12V battery positive
– Black Clip to battery negative
• DVOM:
Back probe the FTV connector. Set the
DVOM for duty cycle percentage and con-
nect between pin A and battery negative
ground.
Is the FTV duty cycle within the specified range?
8 Is the FTV duty cycle above the specified value ? 80 percent Go to Step 12 Go to Step 9
60

9 1. Connect the negative lead of the DVOM to a 12.6V to Go to Step 12 Go to Step 10
know good engine ground. 15.1V
2. Using the positive lead of the DVOM back
probe Pin B at the PTV connector.
Was the PTV voltage within the specified range?
10 1. Turn the engine OFF. Go to Step 16 Go to Step 11
2. Disconnect the ECM connector C001.
3. Disconnect the PTV electrical connector.
4. Check the PTV ground circuit terminal A for
continuity to the ECM connector pin number
2.
5. Check the PTV ground circuit in Terminal A
for short to ignition power or ground.
11 Using the DVOM measure the resistance at the 16 to 24 Go to Step 17 Go to Step 19
PTV terminals.
Was the resistance measured within

specification?
12 1. Connect the negative lead of the DVOM to 12.6V to Go to Step 14 Go to Step 13
battery negative. 15.1V
2. Using the positive lead of the DVOM back
probe pin A at the FTV connector.
Was the FTV voltage within the specified range?
13 1. Turn the engine OFF. Go to Step 16 Go to Step 18
2. Disconnect the ECM connector C001.
3. Disconnect the FTV electrical connector.
4. Check the FTV ground circuit terminal A for
continuity to the ECM connector pin 2.
5. Check the FTV ground circuit in Terminal A
for short to ignition power or ground.
14 Using the DVOM measure the resistance at the 16 to 24 Go to Step 18 Go to Step 20
FTV terminals.
Was the resistance measured within

specification?
15 Replace the ECM. Refer to Electronic Control Go to Step 21
Module (ECM) Replacement.

16 Repair the open or damaged circuit. Go to Step 21
61

17 Check the vacuum hose to the PTV for kinks, Go to Step 21 Go to Step 15
obstruction or leakage.

18 Check the fuel hose to the FTV for kinks, Go to Step 21 Go to Step 15
obstruction or leakage.

19 Replace the PTV. Refer to Pressure Trim Valve Go to Step 21
(PTV) Replacement.

20 Replace the FTV. Refer to Fuel Trim Valve (FTV) Go to Step 21
Solenoid Replacement.

21 1. Return the fuel system to normal operating 20 to 80 Go to Step 25 Go to Step 22
condition. percent
2. Observe the duty cycle reading.
3. Raise the engine speed to approximately 2500
rpm.
Is the duty cycle in the specified range?
22 Check all vacuum hoses and mixer connections Go to Step 21 Go to Step 23
for leakage.

23 Replace mixer. Refer to Mixer Replacement. Go to Step 21

24 The fuel control system is operating normally. System OK
Refer to LPG Symptom Diagnosis.
1. Disconnect all test equipment.
2. If you were sent to this routine by another
diagnostic chart, return to the previous diag-
nostic procedure
3. Using a liquid leak detection solution leak
check any fuel system repairs made.
62
900 SRM 1088 Gasoline System Diagnosis
Gasoline System Diagnosis

FUEL SYSTEM DESCRIPTION, 3.0L ONLY FUEL SYSTEM DESCRIPTION, 4.3L ONLY
The ECM receives information from various engine The ECM receives information from various engine
sensors in order to control the operation of the fuel sensors in order to control the operation of the fuel
injectors. The electric fuel pump prevents fuel flow injectors. The electric fuel pump prevents fuel flow
unless the engine is cranking or running. During unless the engine is cranking or running. During
key ON, the electric fuel pump receives a 2-second key ON, electric fuel pump receives a 2-second prime
prime pulse from the ECM which allows gasoline to pulse from the ECM which allows gasoline to flow
flow from the tank through the fuel filter and fuel from the tank through fuel filter and fuel lines to the
lines to the throttle body fuel inlet port. The single fuel rails where the pressure is regulated. With Igni-
injector is mounted into the throttle body housing. tion ON and fuel pump running, pressure should be
The throttle body also houses the pressure regulator. 284 to 325 kPa (41 to 47 psi). See Figure 35.
With ignition ON and fuel pump running, pressure
should be 69 to 96 kPa (10 to 14 psi). See Figure 34.
Unused fuel is returned to the fuel tank by a separate

return fuel line.
1. ECM 7. FUEL SUPPLY LINE

2. C001 8. PRESSURE
3. INJECTOR REGULATOR
4. FUEL TANK 9. PRESSURE
5. FUEL PUMP GAUGE
6. FUEL RETURN 10. O 2 SENSOR
1. ECM 7. FUEL SUPPLY LINE LINE
2. C001 8. PRESSURE
3. INJECTOR REGULATOR Figure 35. Gasoline Injection System
4. FUEL TANK 9. PRESSURE
5. FUEL PUMP GAUGE
6. FUEL RETURN 10. O 2 SENSOR
LINE
Figure 34. Gasoline Injection System
63
Gasoline System Diagnosis 900 SRM 1088
When the engine is idling, manifold pressure is low • Step 11: Fuel pressure that drops off during accel-
(high vacuum) and is applied to the pressure regu- eration or cruise may cause a lean fuel condition
lator diaphragm. The vacuum will offset the spring and result in a loss of power, surging, or misfire.
pressure and result in very low fuel pressure. Fuel This condition can be diagnosed using a diagnos-
pressures at idle will vary somewhat depending on tic tool. If the fuel in the system is very lean, the
barometric pressure, but should be less then pump HEGO sensor will stop toggling and output voltage
pressure. will drop below 300 mV. Also the injector pulse will
increase.
Unused fuel is returned to the fuel tank by a separate • Step 14: Fuel pressure below 69 kPa (10 psi) for
return fuel line. the 3.0L engine and 284 kPa (41 psi) for the 4.3L
engine may cause a lean fuel condition and may
The fuel pump pressure test port is located on the
set a DTC. Driveablity conditions can include hard
fuel rail.
starting cold, hesitation, and lack of power or mis-
fire.
DIAGNOSTIC AIDS
This procedure is intended to diagnose a vehicle op- CAUTION
erating on gasoline. If the vehicle will not continue to Do not allow the pressure to exceed 137 kPa
run on gasoline, refer to Hard Start for preliminary (20 psi) for the 3.0L engine and 414 kPa
checks. Before proceeding with this procedure, ver- (60 psi) for the 4.3L engine, as damage to the
ify that the vehicle has a sufficient quantity of fuel. regulator may result.
Tools Required • Step 15: Restricting the fuel return line causes the
fuel pressure to build above the regulated pressure.
• Fuel line shutoff adaptor or suitable shutoff valve With battery voltage applied to the pump, pressure
• Fuel pressure gauge should rise above 96 kPa (14 psi) for the 3.0L en-
gine and 325 kPa (47 psi) for the 4.3L engine, as
Diagnostic Tool the valve in the return line is partially closed.
• Laptop computer (see Electronic Control Mod- • Step 17: Fuel pressure above 96 kPa (14 psi) for
ule (ECM) Diagnostic Troubleshooting, GM the 3.0L engine and 325 kPa (47 psi) for the 4.3L
3.0L and 4.3L EPA Compliant Engines 2200 engine, may cause a rich fuel condition and set a
SRM 1090). DTC. Driveability may include hard starting, fol-
lowed by black smoke and a strong sulphur smell
Test Description in the exhaust.
• Step 18: This test is to determine if the high fuel
The steps listed below refer to step numbers on the pressure is due to a restricted fuel return line or a
Table 7 and Table 8: faulty fuel pressure regulator.
• Step 21: 3.0L engine: The pressure regulator can
• Step 4: Connect fuel pressure gauge as shown in be removed and any debris or foreign material re-
Figure 34. Wrap a shop towel around the fuel con- moved.
nection to absorb any small amount of fuel leakage • Step 21: 4.3L engine: The pressure regulator may
that may occur when installing the gauge. With be fitted with a screen which is designed to trap
ignition ON and the fuel pump running, pressure contaminants introduced during engine assembly.
should be 69 to 96 kPa (10 to 14 psi) for the 3.0L en- If dirty it can be removed with a small pick and
gine and 284 to 325 kPa (41 to 47 psi) for the 4.3L discarded without potential harm to the regulator.
engine. This pressure is controlled by spring pres- • Step 23: A system that does not hold pressure is
sure within the regulator assembly. caused by one of the following:
• Step 6: 4.3L only: When the engine is idling, man- – Leaking fuel pump check ball
ifold pressure is low (high vacuum) and is applied – Leaking fuel feed hose
to the pressure regulator diaphragm. The vacuum – Leaking valve/seat within the pressure regulator
will offset spring pressure and result in a lower – Leaking injector
pressure. Fuel pressure at idle will vary somewhat
depending on barometric pressure, but should be
less then the pressure noted in step 4.
64
• Step 26: A leaking injector can best be determined

by checking for a fouled or saturated spark plug(s). WARNING
If a leaking injector cannot be determined by a To reduce the risk of fire or personal
fouled or saturated plug, the following procedure injury that may result from fuel spray
should be used: on the engine, make sure fuel rail is po-
1. Remove the throttle body housing leaving the sitioned over injector port and injector
fuel lines connected. retaining clips are intact.
2. Lift the throttle body enough to see the injector
nozzle. 3. Pressurize the fuel system and observe injector
nozzle.
Table 7. Gasoline Fuel System Diagnosis, 3.0L Only

diagnostic chart?
check. applicable
DTC table.
3 Verify that the gasoline fuel tank has a minimum Go to Step 4 Add Fuel.
of 1/4 tank of fuel.

4 1. Connect a fuel pressure gauge at the fuel sup- 69 to 96 kPa Go to Step 5 Go to Step 10
ply line. (10 to 14 psi)
2. Turn ignition ON, fuel pump will run.
3. Note the pressure.
4. Turn ignition OFF, pressure may vary
slightly then hold steady.
Is pressure within specified values?
5 Did the fuel pressure hold steady after the pump Go to Step 6 Go to Step 22
stopped?
6 1. Start engine and allow it to warm to normal 21 to 69 kPa Go to Step 27 Go to Step 7
operating temperature at idle. (3 to 10 psi)
2. Fuel pressure noted in step 4 should drop.
Did the pressure drop by the specified value?
7 1. Disconnect the vacuum hose from the pres- 21 to 69 kPa Go to Step 8 Go to Step 9
sure regulator. (3 to 10 psi)
2. With the engine idling, apply 305 to 356 mm
(12 to 14 in.) of vacuum to the pressure regu-
lator, pressure should drop.
8 Locate and repair loss of vacuum to the pressure Go to Step 27
regulator.
65
Table 7. Gasoline Fuel System Diagnosis, 3.0L Only (Continued)

9 Replace the pressure regulator. Go to Step 27

10 Is pressure less then specified value? 69 to 96 kPa Go to Step 14 Go to Step 11
(10 to 14 psi)
11 With the fuel pressure gauge installed, start 69 to 96 kPa Go to Step 12 Go to Step 14
engine and accelerate with load. (10 to 14 psi)
Is pressure less then specified value?

12 1. Check for restricted fuel filter. Go to Step 27 Go to Step 13
2. Check for restricted fuel supply line from
pump.
3. Check for restricted fuel pump strainer.
4. Check for leaking fuel supply line from pump.
5. Ensure fuel pump is correct.
13 Replace the fuel pump. Step 27

14 With the ignition OFF: 96 kPa Go to Step 9 Go to Step 15
1. Install a 10-amp fused jumper to the B+ ter- (14 psi)
minal.
2. Install a suitable shutoff valve into the fuel
return line at the throttle body.
3. Slowly close the valve.
4. The pressure should rise.
NOTE: Do not exceed 137 kPa (20 psi).
Did the pressure rise?

15 1. Check for restricted fuel pump strainer. Go to Step 27 Go to Step 16
2. Check for leaking fuel supply line from pump.
16 Replace the fuel pump. Go to Step 27

17 Is pressure greater then specified value? 69 to 96 kPa Go to Step 15 Go to Step 12
(10 to 14 psi)
66

18 1. Disconnect the fuel return hose at the throttle 69 to 96 kPa Go to Step 19 Go to Step 20
body. (10 to 14 psi)
2. Attach a length of hose to the return line at
the rail.
3. Place the other end of the hose in an approved
gasoline container.
4. Turn ignition OFF for 10 seconds.
5. Turn ignition ON.
Is pressure within specified value?
19 The fuel return hoses are plugged or restricted. Go to Step 24
Locate and repair the problem.
20 Check for restricted throttle body fuel line Go to Step 27 Go to Step 21
fitting or plugged fuel return in the throttle body
housing.

21 Remove pressure regulator and check for Go to Step 27 Go to Step 9
restriction.

22 Fuel pressure is within specification but does Go to Step 23
not hold pressure.
23 1. Install fuel line shutoff adapter or suitable Go to Step 24 Go to Step 25
valve to close off fuel supply.
2. Make sure valve is open.
3. With the ignition OFF, install a 10-amp fused
jumper to the B+ terminal.
4. Pressure should rise.
5. Disconnect the jumper and close valve.
Did pressure hold?
24 Check for leaking fuel pump supply line. Go to Step 27 Go to Step 13
Was there a problem found?

25 1. Open valve in fuel pressure line. Go to Step 9 Go to Step 26
2. Connect test jumper and wait for pressure to
build.
3. Disconnect jumper and close valve in fuel
pressure line.
Does pressure hold?
67

26 Replace leaking injector. See Injector Go to Step 27
Replacement, Gasoline 3.0L Only.

2. Install the test port cap.
4. Verify engine is in closed loop and no MIL is
on.
Table 8. Gasoline Fuel System Diagnosis, 4.3L Only

diagnostic chart?
check. applicable
DTC table.
3 Verify that the gasoline fuel tank has a Go to Step 4 Add Fuel.
minimum of 1/4 tank of fuel.

4 1. Connect a fuel pressure gauge at the 284 to 325 kPa Go to Step 5 Go to Step 10
Schrader valve located on the fuel rail. (41 to 47 psi)
2. Turn ignition ON, fuel pump will run.
3. Note the pressure.
4. Turn ignition OFF. Pressure may vary
slightly then hold steady.
Is pressure within specified values?
5 Did the fuel pressure hold steady after the Go to Step 6 Go to Step 22
pump stopped?
6 1. Start engine and allow it to warm to normal 21 to 69 kPa (3 Go to Step Go to Step 7
operating temperature at idle. to 10 psi) 27
2. Fuel pressure noted in step 4 should drop.
7 1. Disconnect the vacuum hose from the pres- 21 to 69 kPa (3 Go to Step 8 Go to Step 9
sure regulator. to 10 psi)
2. With the engine idling, apply 305 to 356 mm
(12 to 14 in.) of vacuum to the pressure
regulator, pressure should drop.
68

8 Locate and repair loss of vacuum to the Go to Step
pressure regulator. 27

9 Replace the pressure regulator. Go to Step
27
10 Is pressure less then specified value? 284 to 325 kPa Go to Step Go to Step 11
(41 to 47 psi) 14
11 With the fuel pressure gauge installed, start 284 to 325 kPa Go to Step Go to Step 14
engine and accelerate with load. (41 to 47 psi) 12
Is pressure less then specified value?

12 1. Check for restricted fuel filter. Go to Step Go to Step 13
2. Check for restricted fuel supply line from 27
pump.
13 Replace the fuel pump. Go to Step
27
14 With the ignition OFF: 325 kPa Go to Step 9 Go to Step 15
1. Install a 10-amp fused jumper to the B+ ter- (47 psi)
minal.
2. Slowly pinch the fuel return line.
3. The pressure should rise.
NOTE: Do not exceed 414 kPa (60 psi).
Did the pressure rise?

15 1. Check for restricted fuel pump strainer. Go to Step Go to Step 16
2. Check for leaking fuel supply line from 27
pump.
16 Replace the fuel pump. Go to Step
27
17 Is pressure greater then specified value? 284 to 325 kPa Go to Step
(41 to 47 psi) 15
69

18 1. Disconnect the fuel return hose at the throt- 284 to 325 kPa Go to Step Go to Step 20
tle body. (41 to 47 psi) 19
2. Attach a length of hose to the return line at
the rail.
3. Place the other end of the hose in an ap-
proved gasoline container.
4. Turn ignition OFF for 10 seconds.
5. Turn ignition ON.
Is pressure within specified value?
19 The fuel return hoses are plugged or restricted. Go to Step
Locate and repair the problem. 27
20 Check for restricted engine return line. Go to Step Go To Step 21
27
21 Remove pressure regulator and check for Go to Step Go to Step 9
restriction. 27

22 Fuel pressure is within specification, but does Go to Step
not hold pressure. 23
23 1. Install fuel line shutoff adapter or suitable Go to Step Go to Step 25
valve to close off fuel supply. 24
2. Make sure valve is open.
3. With the ignition OFF, install a 10-amp
fused jumper to the B+ terminal.
4. Pressure should rise.
5. Disconnect the jumper and close valve.
Did pressure hold?
24 Check for leaking fuel pump supply line. Go to Step Go to Step 13
27
Was there a problem found?
25 1. Open valve in fuel pressure line. Go to Step 9 Go to Step 26
2. Connect test jumper and wait for pressure
to build.
3. Disconnect jumper and close valve in fuel
pressure line.
Does pressure hold?
70
900 SRM 1088 LPG Symptom Diagnosis

26 Locate and replace the leaking injectors. See Go to Step
Injector Replacement, Gasoline 4.3L Only. 27

2. Install the test port cap.
4. Verify engine is in closed loop and no MIL is
on.
LPG Symptom Diagnosis

This section will help the technician to diagnose fuel to be checked are listed below in Table 9 through Ta-
symptom problems on your lift truck. The symptoms ble 19.
Table 9. Preliminary Checks
Checks Action
Before Using This Section Before using this section, you should have performed an OBD check
and determined that:
1. The ECM and MIL are operating correctly.
2. There are no DTCs stored, or a DTC exists but without a MIL.
Several of the following symptom procedures call for a careful
visual and physical check. The visual and physical checks are very
important. The checks can lead to correcting a problem without
further checks that may save valuable time.
71
LPG Symptom Diagnosis 900 SRM 1088
Table 9. Preliminary Checks (Continued)
Checks Action
LPG Fuel System Check 1. Verify the complaint.
2. Locate the correct symptom table.
3. Check the items indicated under that symptom.
4. Operate the vehicle under the conditions the symptom occurs.
Verify HEGO switching between lean and rich.
NOTE: Normal HEGO switching indicates the LPG fuel system is

in closed loop and operating correctly at that time.
5. If a laptop computer is available, take a snapshot under the con-

dition that the symptom occurs. Verify normal sensor values and
parameters.
Visual and Physical Checks • Check all ECM system fuses and circuit breakers.
• Check the ECM ground for being clean, tight, and in its proper lo-
cation.
• Check the vacuum hoses for splits, kinks, and proper connections.
• Check thoroughly for any type of leak or restriction.
• Check for air leaks at all the mounting areas of the intake manifold
sealing surfaces.
• Check for proper installation of the mixer module assembly.
• Check for air leaks at the mixer assembly.
• Check the ignition wires for the following conditions:
– Cracking
– Hardness
– Proper routing
– Carbon tracking
• Check the wiring for the following items:
– Proper connections, pinches, or cuts.
• The following symptom tables contain groups of possible causes for
each symptom. The order of these procedures is not important. If
the laptop computer readings do not indicate the problems, then
proceed in a logical order, easiest to check or most likely to cause
first.
72
Table 10. Intermittent
Checks Action
Definition: The problem may or may not turn on the MIL or store a DTC.
Preliminary Checks • Refer to Table 9.
• Do not use the DTC tables. If a fault is an intermittent, the use of
the DTC tables may result in the replacement of good parts.
Faulty Electrical Connections or • Faulty electrical connections or wiring can cause most intermittent
Wiring problems.
• Check the suspected circuit for the following conditions:
– Faulty fuse or circuit breaker
– Connectors poorly mated
– Terminals not fully seated in the connector (backed out)
– Terminals not properly formed or damaged
– Terminal to wires poorly connected
– Terminal tension insufficient.
• If necessary, replace all the connector terminals in the problem cir-
cuit in order to ensure the proper contact tension.
• Checking for poor terminal to wire connections requires removing
the terminal from the connector body.
Operational Test If a visual and physical check does not locate the cause of the
problem, drive the vehicle with a laptop computer connected. When
the problem occurs, an abnormal voltage or scan reading indicates
the problem may be in that circuit.
Intermittent Malfunction Indicator The following components can cause intermittent MIL and no
Lamp DTC(s):
• A defective relay, ECM driven solenoid, or a switch that can cause
electrical system interference. Normally, the problem will occur
when the faulty component is operating.
• The improper installation of electrical devices, such as lights, 2-way
radios, electric motors, etc.
• The ignition secondary voltage shorted to a ground.
• The MIL circuit or the diagnostic test terminal intermittently
shorted to ground.
• The ECM grounds.
Loss of DTC Memory To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.
2. Idle the engine until the MIL illuminates.
The ECM should store a TMAP DTC. The TMAP DTC should remain
in the memory when the ignition is turned OFF. If the TMAP DTC
does not store and remain, the ECM is faulty.
73
Table 11. No Start
Checks Action
Definition: The engine cranks but does not start.
Preliminary Checks Refer to Table 9.
ECM Checks • If a laptop computer is available:
– Check for proper communication with the ECM
• Check the 20 Amp in-line fuse in the ECM battery power circuit.
Refer to the Diagrams section for your lift truck.
• Check battery power, ignition power and ground circuits to the
ECM. Refer to the Diagrams section for your lift truck. Verify
voltage and/or continuity for each circuit.
Sensor Checks • Check the TMAP sensor.
• Check the magnetic pickup sensor (rpm).
Fuel System Checks NOTE: A closed LPG manual fuel shut off valve will create a no start
condition.
• Check for air intake system leakage between the mixer and the
throttle body.
• Verify proper operation of the low pressure lock-off solenoids.
• Verify proper operation of the fuel control solenoids.
• Check the fuel system pressures. Refer to LPG System Diagnosis.
• Check for proper mixer air valve operation.
Ignition System Checks NOTE: LPG being a gaseous fuel requires higher secondary ignition
system voltages for the equivalent gasoline operating conditions.
• Check for the proper ignition voltage output.
• Verify that the spark plugs are correct. Refer to the Parts Manual
for your lift truck.
• Check the spark plugs for the following conditions:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Burned electrodes
– Heavy deposits
• Check for bare or shorted ignition wires.
• Check for loose ignition coil connections at the coil.
74
Table 11. No Start (Continued)
Checks Action
Engine Mechanical Checks
CAUTION
The LPG fuel system works on a fumigation principle of fuel
introduction and is more sensitive to intake manifold leakage
than the gasoline fuel supply system.
• Check for the following:
– Vacuum leaks
– Improper valve timing
– Low compression
– Bent pushrods
– Worn rocker arms
– Broken or weak valve springs
– Worn camshaft lobes.
Exhaust System Checks • Check the exhaust system for a possible restriction:
– Inspect the exhaust system for damaged or collapsed pipes.
– Inspect the muffler for signs of heat distress or for possible inter-
nal failure.
• Check for possible plugged catalytic converter. Refer to Restricted
Exhaust System Diagnosis.
75
Table 12. Hard Start
Checks Action
Definition: The engine cranks, but does not start for a long time. The engine does eventually run, or
may start but immediately dies.
• Make sure the operator is using the correct starting procedure.
Sensor Checks • Check the engine coolant temperature sensor with the laptop com-
puter. Compare the engine coolant temperature with the ambient
air temperature on a cold engine. If the coolant temperature read-
ing is more than 5 degrees greater or less than the ambient air tem-
perature on a cold engine, check for high resistance in the coolant
sensor circuit. Refer to DTC 122 and DTC 123 in the section Elec-
tronic Control Module (ECM) Diagnostic Troubleshooting,
GM 3.0L and 4.3L EPA Compliant Engines 2200 SRM 1090.
• Check the crankshaft position (CKP) sensor.
• Check the TPS and FPP sensors.
Fuel System Checks NOTE: A closed LPG manual fuel shutoff valve will create an extended
crank or no start condition.
• Verify the excess flow valve in the LPG manual shutoff valve is not
tripped.
• Check mixer module assembly for proper installation and leakage.
• Verify proper operation of the low pressure lock-off solenoids.
• Verify proper operation of the PTV and FTV.
• Check for air intake system leakage between the mixer and the
throttle body.
• Check the fuel system pressures. Refer to LPG System Diagnosis.
Ignition System Checks NOTE: LPG, being a gaseous fuel, requires higher secondary ignition
system voltages for the equivalent gasoline operating conditions.
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
• Check for moisture in the distributor cap if applicable.
• Check for loose ignition coil connections.
1. If the engine starts but then immediately stalls, check CKP.
2. Check for improper gap, debris or faulty connections.
76
Table 12. Hard Start (Continued)
Checks Action
Engine Mechanical Checks
CAUTION
• Check for the following:
– Vacuum leaks
– Low compression
– Bent pushrods
• Check the intake and exhaust manifolds for casting flash.
nal failure.
Table 13. Cuts Out or Misses
Checks Action
Definition: A surging or jerking that follows engine speed, usually more pronounced as the engine load
increases which is not normally felt above 1500 rpm. The exhaust has a steady spitting sound at idle, low
speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Ignition System Checks • Start the engine.
• Wet down the secondary ignition system with water from a spray
bottle, and look/listen for arcing or misfiring as you apply water.
• Check for proper ignition output voltage.
• Check for a cylinder misfire.
• Remove the spark plugs in these cylinders and check for the follow-
ing conditions:
– Insulation cracks
– Wear
– Improper gap
– Heavy deposit
• Visually/Physically inspect the secondary ignition for the following:
– Ignition wires for arcing, cross-firing and proper routing
– Ignition coils for cracks or carbon tracking
77
Table 13. Cuts Out or Misses (Continued)
Checks Action
Engine Mechanical Checks • Perform a cylinder compression check.
• Check the engine for the following:
– Bent pushrods
– Broken or weak valve springs.
• Check the intake and exhaust manifold passages for casting flash.
Fuel System Checks • Check for a restricted fuel filter, contaminated fuel, or improper fuel
pressure. Refer to LPG System Diagnosis.
• Check the condition of the wiring to the low pressure lock-off sole-
noid.
Additional Checks Check for electromagnetic interference (EMI) and radio frequency
interference (RFI).
• EMI/RFI on the reference circuit can cause a missing condition.
• Monitoring the engine rpm with a laptop computer can detect an
EMI/RFI.
• A sudden increase in the rpm with little change in the actual engine
rpm, indicates EMI/RFI is present.
• If the problem exists, check the routing of the secondary wires and
the ground circuit.
Table 14. Hesitation, Sag, or Stumble
Checks Action
Definition: The vehicle has a momentary lack of response when depressing the accelerator. The condition
can occur at any vehicle speed. The condition may cause the engine to stall if it’s severe enough.
Fuel System Checks • Check the fuel pressure. Refer to LPG System Diagnosis.
• Check for low fuel pressure during a moderate or full throttle ac-
celeration. If the fuel pressure drops below specification, there is
possibly a faulty low pressure regulator or a restriction in the fuel
system.
• Check the MAP sensor response and accuracy.
• Check LPL electrical connection.
• Check the mixer air valve for sticking or binding.
• Check the mixer module assembly for proper installation and leak-
age.
• Check the PTV and FTV.
78
Table 14. Hesitation, Sag, or Stumble (Continued)
Checks Action
Ignition System Checks
CAUTION
LPG, being a gaseous fuel, requires higher secondary ignition
system voltages for the equivalent gasoline operating condi-
tions. If a problem is reported on LPG and not gasoline, do not
discount the possibility of a LPG only ignition system failure
and test the system accordingly.
• Check for faulty spark plug wires.
• Check for fouled spark plugs.
Additional Check • Check for manifold vacuum or air induction system leaks.
• Check the generator output voltage.
Table 15. Backfire
Checks Action
Definition: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.
Ignition System Checks NOTE: LPG, being a gaseous fuel, requires higher secondary igni-
tion system voltages for the equivalent gasoline operating conditions.
The ignition system must be maintained in peak condition to prevent
backfire.
• Check for the proper ignition coil output voltage.
• Check the spark plug wires by connecting an ohmmeter to the ends
of each wire in question. If the meter reads over 30,000 Ohms, re-
place the wires.
• Check the connection at each ignition coil.
• Check for deteriorated spark plug wire insulation.
• Remove the plugs and inspect them for the following conditions:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
79
Table 15. Backfire (Continued)
Checks Action
Engine Mechanical Check
CAUTION
than a gasoline fuel supply system.
– Engine compression
– Manifold vacuum leaks
– Intake manifold gaskets
– Sticking or leaking valves
– Exhaust system leakage
• Check the intake and exhaust system for casting flash or other re-
strictions.
Fuel System Checks Perform a fuel system diagnosis. Refer to LPG System Diagnosis.
Table 16. Lack of Power, Sluggishness, or Sponginess
Checks Action
Definition: The engine delivers less than expected power. There is little or no increase in speed when
partially applying the accelerator pedal.
Preliminary Checks • Refer to Preliminary Checks.
• Refer to the On-Board Diagnostics table in the section Electronic
Control Module (ECM) Diagnostic Troubleshooting, GM 3.0L
and 4.3L EPA Compliant Engines 2200 SRM 1090.
• Compare the vehicle with a similar unit. Do not compare the power
output of the vehicle operating on LPG to a vehicle operating on
gasoline as the fuels do have different drive feel characteristics.
• Remove the air filter and check for dirt or restriction.
• Check the vehicle transmission.
pressure. Refer to LPG System Diagnosis.
• Check for the proper ignition output voltage.
• Check all air inlet ducts for condition and proper installation.
• Check for fuel leaks between the LPR and the mixer.
• Verify that the LPG tank manual shutoff valve is fully open.
• Verify that liquid fuel (not vapor) is being delivered to the LPR.
Sensor Checks • Check the HEGO sensor for contamination and performance.
Check for proper operation of the MAP sensor.
• Check for proper operation of the TPS and FPP sensors.
80
Table 16. Lack of Power, Sluggishness, or Sponginess (Continued)
Checks Action
nal failure.
– Check for possible plugged catalytic converter. Refer to Restricted
Engine Mechanical Check Check the engine for the following:
• Engine compression
• Valve timing
• Improper or worn camshaft.
Additional Checks • Check the ECM grounds for being clean, tight, and in their proper
locations.
• If all procedures have been completed and no malfunction has been
found, review and inspect the following items:
– Visually and physically, inspect all electrical connections within
the suspected circuit and/or systems.
– Check the laptop computer data.
Table 17. Poor Fuel Economy
Checks Action
Definition: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the
economy is noticeably lower than it was on this vehicle at one time, as previously shown by refueling records.
• Check the air cleaner element (filter) for dirt or being plugged.
• Visually and physically check the vacuum hoses for splits, kinks,
and proper connections.
• Check the operators driving habits for the following items:
– Is there excessive idling or stop and go driving?
– Are the tires at the correct air pressure?
– Are excessively heavy loads being carried?
– Is there often rapid acceleration?
• Suggest to the owner to fill the fuel tank and to recheck the fuel
economy.
• Suggest that a different operator use the equipment and record the
results.
Fuel System Checks • Check the LPR fuel pressure. Refer to LPG System Diagnosis.
• Check the fuel system for leakage.
Sensor Checks Check the TMAP sensor.
81
Table 17. Poor Fuel Economy (Continued)
Checks Action
Ignition System Checks • Verify that the spark plugs are correct. Refer to the Parts Manual
• Check the spark plugs. Remove the plugs and inspect them for the
following conditions:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
• Check the ignition wires for the following items:
– Cracking
– Hardness
– Proper connections
Cooling System Checks Check the engine thermostat for always being open or for the wrong
heat range.
Additional Check • Check the transmission shift pattern.
• Check for dragging brakes.
Table 18. Rough, Unstable, Incorrect Idle, or Stalling
Checks Action
Definition: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The
engine idle speed may vary in rpm. Either condition may be severe enough to stall the engine.
Sensor Checks • Check for silicon contamination from fuel or improperly used
sealant. The sensor will have a white powdery coating. The
sensor will result in a high but false signal voltage (rich exhaust
indication). The ECM will reduce the amount of fuel delivered to
the engine causing a severe driveability problem.
• Check the HEGO performance.
• Check the TMAP sensor response and accuracy.
Fuel System Checks • Check for rich or lean symptom that causes the condition. Drive
the vehicle at the speed of the complaint. Monitoring the oxygen
sensors will help identify the problem.
• Check for a sticking mixer air valve.
• Verify proper operation of the PTV and FTV.
• Perform a cylinder compression test.
• Check the LPR fuel pressure. Refer to LPG System Diagnosis.
• Check mixer module assembly for proper installation and connec-
tion.
82
Table 18. Rough, Unstable, Incorrect Idle, or Stalling (Continued)
Checks Action
Ignition System Checks • Check for the proper ignition output voltage.
– Wet plugs
– Cracks
– Wear
– Improper gap
– Blistered insulators
– Heavy deposits
place the wires.
Additional Checks
CAUTION
The LPG Fuel system works on a fumigation principle of fuel
• Check for vacuum leaks. Vacuum leaks can cause a higher than
normal idle and low throttle angle control command.
• Check the ECM grounds for being clean, tight, and in their proper
locations.
• Check the battery cables and ground straps. They should be clean
and secure. Erratic voltage may cause all sensor readings to be
skewed resulting in poor idle quality.
Engine Mechanical Check • Check the engine for the following:
– Broken motor mounts
– Low compression
– Bent pushrods
– Worn camshaft lobes
83
Table 19. Surges or Chuggles
Checks Action
Definition: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it
speeds up and slows down with no change in the accelerator pedal.
• Be sure the driver understands the torque converter clutch opera-
tion.
Sensor Checks Check the HEGO performance.
• Check the fuel pressure while the condition exists. Refer to LPG
System Diagnosis.
• Verify proper fuel control solenoid operation.
• Verify that the LPG manual shutoff valve is fully open.
• Check the in-line fuel filter for restrictions.
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
• Check the CKP sensor.
locations.
• Check the vacuum hoses for kinks or leaks.
• Check transmission
84
900 SRM 1088 Gasoline Symptom Diagnosis
Gasoline Symptom Diagnosis

This section will help the technician to diagnose gaso- symptoms to be checked are listed below in Table 20
line fuel symptom problems on your lift truck. The through Table 30.
Table 20. Preliminary Checks
Checks Action
Before Using This Section Before using this section, you should have performed an OBD check
and determined that:
1. The ECM and MIL are operating correctly.
2. There are no DTCs stored or a DTC exists but without a MIL.
Several of the following symptom procedures call for a careful
visual and physical check. The visual and physical checks are very
important. The checks can lead to correcting a problem without
further checks that may save valuable time.
Gasoline Fuel System Check 1. Verify the complaint.
2. Locate the correct symptom table.
3. Check the items indicated under that symptom.
4. Operate the vehicle under the conditions the symptom occurs.
Verify HEGO switching between lean and rich.
NOTE: Normal HEGO switching indicates the gasoline fuel sys-

tem is in closed loop and operating correctly at that time.
5. If a laptop computer is available, take a snapshot under the con-

dition that the symptom occurs. Verify normal sensor values and
parameters.
Visual and Physical Checks • Check all ECM system fuses and circuit breakers.
• Check the ECM ground for being clean, tight, and in its proper lo-
cation.
• Check the vacuum hoses for splits, kinks, and proper connections.
• Check thoroughly for any type of leak or restriction.
• Check for air leaks at all the mounting areas of the intake manifold
sealing surfaces.
• Check for air leaks at the mixer assembly.
• Check the ignition wires for the following conditions:
– Cracking
– Hardness
– Proper routing
– Carbon tracking
• Check the wiring for the following items:
– Proper connections, pinches, or cuts
• The following symptom tables contain groups of possible causes for
each symptom. The order of these procedures is not important. If
the laptop computer readings do not indicate the problems, then
proceed in a logical order, easiest to check or most likely to cause
first.
85
Gasoline Symptom Diagnosis 900 SRM 1088
Table 21. Intermittent
Checks Action
Definition: The problem may or may not turn on the MIL or store a DTC.
• Do not use the DTC tables. If a fault is an intermittent, the use of
the DTC tables may result in the replacement of good parts.
Faulty Electrical Connections or • Faulty electrical connections or wiring can cause most intermittent
Wiring problems.
• Check the suspected circuit for the following conditions:
– Faulty fuse or circuit breaker
– Connectors poorly mated
– Terminals not fully seated in the connector (backed out)
– Terminals not properly formed or damaged
– Terminal to wires poorly connected
– Terminal tension insufficient
• Carefully remove all the connector terminals in the problem circuit
in order to ensure the proper contact tension. If necessary, replace
all the connector terminals in the problem circuit in order to ensure
the proper contact tension.
• Checking for poor terminal to wire connections requires removing
the terminal from the connector body.
Operational Test If a visual and physical check does not locate the cause of the
problem, drive the vehicle with a laptop computer connected. When
the problem occurs, an abnormal voltage or scan reading indicates
the problem may be in that circuit.
Intermittent Malfunction Indicator The following components can cause intermittent MIL and no
Lamp DTC(s):
• A defective relay, ECM driven solenoid, or a switch that can cause
electrical system interference. Normally, the problem will occur
when the faulty component is operating.
• The improper installation of electrical devices, such as lights, 2-way
radios, electric motors, etc.
• The ignition secondary voltage shorted to a ground.
• The MIL circuit or the diagnostic test terminal intermittently
shorted to ground.
• The ECM grounds.
Loss of DTC Memory To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.
2. Idle the engine until the Malfunction Indicator Lamp illuminates.
The ECM should store a TMAP DTC. The TMAP DTC should remain
in the memory when the ignition is turned OFF. If the TMAP DTC
does not store and remain, the ECM is faulty.
86
Table 22. No Start
Checks Action
Definition: The engine cranks but does not start.
ECM Checks • If a laptop computer is available:
– Check for proper communication with the ECM
• Check the 20 Amp in-line fuse in the ECM battery power circuit.
Refer to the Diagrams section for your lift truck.
• Check battery power, ignition power and ground circuits to the
ECM. Refer to the Diagrams section for your lift truck. Verify
voltage and/or continuity for each circuit.
Sensor Checks • Check the TMAP sensor.
Fuel System Checks • Check for fuel pump electrical circuit.
• Verify proper fuel pump pressure.
• Verify proper fuel rail pressure.
• Refer to the Gasoline System Diagnosis.
• Check electrical connections at the injectors.
Ignition System Checks • Check for the proper ignition voltage output.
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
• Check for loose ignition coil connections at the coil.
Engine Mechanical Checks • Check for the following:
– Vacuum leaks
– Low compression
– Bent push rods
nal failure.
87
Table 23. Hard Start
Checks Action
Definition: The engine cranks, but does not start for a long time. The engine does eventually run, or
may start but immediately dies.
• Make sure the vehicle’s operator is using the correct starting pro-
cedure.
Sensor Checks • Check the engine coolant temperature (ECT) sensor with the lap-
top computer. Compare the engine coolant temperature with the
ambient air temperature on a cold engine. If the coolant tempera-
ture reading is more than 5 degrees greater or less than the ambi-
ent air temperature on a cold engine, check for high resistance in
the coolant sensor circuit. Refer to DTC 122 and DTC 123 in the
section Electronic Control Module (ECM) Diagnostic Trou-
bleshooting, GM 3.0L and 4.3L EPA Compliant Engines 2200
SRM 1090.
• Check the TPS sensor.
Fuel System Checks • Check the fuel pump electrical circuit.
• Refer to Gasoline System Diagnosis.
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
• Check for moisture in the distributor cap if applicable.
• Check for loose ignition coil connections.
1. If the engine starts but then immediately stalls, check CKP.
2. Check for improper gap, debris, or faulty connections.
88
Table 23. Hard Start (Continued)
Checks Action
Engine Mechanical Checks • Check for the following:
– Vacuum leaks
– Low compression
– Bent push rods
• Check the intake and exhaust manifolds for casting flash.
nal failure.
Table 24. Cuts Out or Misses
Checks Action
Definition: A surging or jerking that follows engine speed, usually more pronounced as the engine load
increases, which is not normally felt above 1500 rpm. The exhaust has a steady spitting sound at idle, low
speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Ignition System Checks • Start the engine.
• Wet down the secondary ignition system with water from a spray
bottle, and look/listen for arcing or misfiring as you apply water.
• Check for proper ignition output voltage.
• Remove the spark plugs in these cylinders and check for the follow-
ing conditions:
– Insulation cracks
– Wear
– Improper gap
– Heavy deposits
• Visually/Physically inspect the secondary ignition for the following:
– Ignition wires for arcing, cross-firing, and proper routing
– Ignition coils for cracks or carbon tracking
89
Table 24. Cuts Out or Misses (Continued)
Checks Action
Engine Mechanical Checks • Perform a cylinder compression check.
– Bent push rods
• Check the intake and exhaust manifold passages for casting flash.
Fuel System Checks • Check the fuel system - plugged fuel filter, low fuel pressure, etc.
Refer to Gasoline System Diagnosis.
• Check the condition of the wiring to the fuel pump and injectors.
Additional Check Check for electromagnetic interference (EMI) and radio frequency
interference (RFI).
• EMI/RFI on the reference circuit can cause a missing condition.
• Monitoring the engine rpm with a laptop computer can detect an
EMI/RFI.
• A sudden increase in the rpm with little change in the actual engine
rpm, indicates EMI/RFI is present.
• If the problem exists, check the routing of the secondary wires and
the ground circuit.
Table 25. Hesitation, Sag, or Stumble
Checks Action
Definition: The vehicle has a momentary lack of response when depressing the accelerator. The condition
can occur at any vehicle speed. The condition may cause the engine to stall if it’s severe enough.
Fuel System Checks • Check the fuel pump electrical circuit.
• Check for faulty spark plug wires.
• Check for fouled spark plugs.
Additional Check • Check for manifold vacuum or air induction system leaks
90
Table 26. Backfire
Checks Action
Definition: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.
Ignition System Checks • Check for the proper ignition coil output voltage.
place the wires.
• Check the connection at each ignition coil.
• Check for deteriorated spark plug wire insulation.
• Remove the plugs and inspect them for the following conditions:
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
Engine Mechanical Check • Check the engine for the following:
– Engine compression
– Manifold vacuum leaks
– Intake manifold gaskets
– Sticking or leaking valves
– Exhaust system leakage
• Check the intake and exhaust system for casting flash or other re-
strictions.
Fuel System Checks Perform a fuel system diagnosis. Refer to Gasoline System
Diagnosis.
91
Table 27. Lack of Power, Sluggishness, or Sponginess
Checks Action
Definition: The engine delivers less than expected power. There is little or no increase in speed when
partially applying the accelerator pedal.
• Compare the customer’s vehicle with a similar unit. Make sure the
customer has an actual problem.
• Remove the air filter and check for dirt or restriction.
• Check the vehicle transmission.
pressure. Refer to Gasoline System Diagnosis.
• Check for the proper ignition output voltage.
• Check the fuel pump electrical circuit.
• Refer to the Gasoline Fuel System Diagnosis.
Sensor Checks • Check the HEGO sensor for contamination and performance.
• Check for proper operation of the MAP sensor.
• Check for proper operation of the TPS and FPP sensors.
nal failure.
– Check for possible plugged catalytic converter.
• Engine compression
• Valve timing
• Improper or worn camshaft.
Additional Check • Check the ECM grounds for being clean, tight, and in their proper
locations.
• If all procedures have been completed and no malfunction has been
found, review and inspect the following items:
– Visually and physically inspect all electrical connections within
the suspected circuit and/or systems.
– Check the laptop computer data.
92
Table 28. Poor Fuel Economy
Checks Action
Definition: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the
economy is noticeably lower than it was on this vehicle at one time, as previously shown by refueling records.
• Check the air cleaner element (filter) for dirt or being plugged.
• Visually/Physically check the vacuum hoses for splits, kinks, and
proper connections.
• Check the operators driving habits for the following items:
– Is there excessive idling or stop and go driving?
– Are the tires at the correct air pressure?
– Are excessively heavy loads being carried?
– Is their often rapid acceleration?
• Suggest to the owner to fill the fuel tank and to recheck the fuel
economy.
• Suggest that a different operator use the equipment and record the
results.
Fuel System Checks • Check the fuel rail pressure. Refer to Gasoline System Diagnosis.
• Check the fuel system for leakage.
Sensor Checks Check the TMAP sensor.
Ignition System Checks • Verify that the spark plugs are correct. Refer to the Parts Manual
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
• Check the ignition wires for the following items:
– Cracking
– Hardness
– Proper connections
Cooling System Checks Check the engine thermostat for always being open or for the wrong
heat range.
Additional Check • Check the transmission shift pattern.
• Check for dragging brakes.
93
Table 29. Rough, Unstable, Incorrect Idle, or Stalling
Checks Action
Definition: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The
engine idle speed may vary in rpm. Either condition may be severe enough to stall the engine.
Sensor Checks • Check for silicon contamination from fuel or improperly used
sealant. The sensor will have a white powdery coating. The
sensor will result in a high but false signal voltage (rich exhaust
indication). The ECM will reduce the amount of fuel delivered to
the engine causing a severe driveability problem.
• Check the HEGO sensor performance.
• Check the TMAP sensor response and accuracy.
• Verify proper operation of the injectors.
• Perform a cylinder compression test.
• Check the fuel rail pressure. Refer to Gasoline System Diagnosis.
• Check injector electrical connections.
– Wet plugs
– Cracks
– Wear
– Improper gap
– Blistered insulators
– Heavy deposits
place the wires.
locations.
• Check the battery cables and ground straps. They should be clean
and secure. Erratic voltage may cause all sensor readings to be
skewed resulting in poor idle quality.
• Broken motor mounts
• Improper valve timing
• Low compression
• Bent push rods
• Worn rocker arms
• Broken or weak valve springs
• Worn camshaft lobes
94
900 SRM 1088 Wire Harness Repair
Table 30. Surges or Chuggles
Checks Action
Definition: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it
speeds up and slows down with no change in the accelerator pedal.
• Be sure the driver understands the torque converter clutch opera-
tion.
Sensor Checks Check the HEGO performance.
• Check the fuel rail pressure while the condition exists. Refer to
Gasoline System Diagnosis.
• Verify check injector electrical connections.
• Check the in-line fuel filter for restrictions.
– Wet plugs
– Cracks
– Wear
– Improper gap
– Heavy deposits
Additional Check • Check the ECM grounds for being clean, tight, and in their proper
locations.
• Check the vacuum hoses for kinks or leaks.
• Check Transmission.
Wire Harness Repair

ON VEHICLE SERVICE WIRING HARNESS passenger compartment. A wiring harness must be
REPAIR replaced with a wire harness that has the same part
number. If a repair (wire splice) must be made to a
NOTE: The most common fault that occurs in an wiring harness, replacement wire must have a high-
electronic engine control system is caused by a bad temperature insulation.
connection in the wiring. Work carefully and make
sure that connectors are not damaged during trou- The signal wires in the electronic control system have
bleshooting. a low voltage and low current. All splice wires must
be high quality so that a fault is not made in the cir-
The ECM wire harness electrically connects the ECM cuit by the wire splice. Use solder on the wire splices
to solenoids, switches, and sensors in the engine and when possible. See Figure 36.
95
Wire Harness Repair 900 SRM 1088
wires between connectors for circuit checking.

NEVER probe through the Weather-Pack seals.
Be careful when using a probe to check the voltages

on the terminals in a connector. It is easy to cause
a short circuit between two terminals with opposite
voltages. Electronic components can be easily dam-
aged by a short circuit. Always use a Jumper With
1. SPLICE AND SOLDER A 15 Amp Fuse between connectors when check-
Figure 36. Splice and Solder ing circuits. Never damage the insulation or a seal
on a connector when making a check or doing trou-
Some connectors are made as a one-piece unit. A bleshooting. The Connector Test Adapter Kit has
damaged one-piece connector must be replaced with a variation of adapters and connectors that can be
a wire splice into the wiring harness. Some connec- used when troubleshooting a circuit.
tors can be replaced or a terminal within the connec-
tors can be replaced. These connectors are described When Troubleshooting, open circuits are often diffi-
in the paragraphs under Connectors and Terminals. cult to see because of dirt, corrosion, or a terminal
that is not in alignment in its socket. When Trou-
CONNECTORS AND TERMINALS bleshooting for an open circuit, always check for loose
connections and a terminal that can have corrosion.
A fault that is not regular nor constant can also be
CAUTION caused by a loose connection or a terminal that has
Use care when probing a connector or replac- corrosion.
ing terminals in them. It is possible to short
between opposite terminals. If this happens to Always verify the type of connector to be repaired.
the wrong terminal pair, it is possible to dam- Some smaller models of connectors look similar but
age certain components. Always use jumper have a different construction.
Twisted/Shielded Cable Repair

STEP 1.
Remove outer jacket.
STEP 2.
Unwrap aluminum mylar tape. Do not remove mylar
tape.
1. DRAIN WIRE
2. OUTER JACKET
3. MYLAR
96
STEP 3.
Untwist conductors and strip insulation as necessary.
STEP 4.
Splice wires using splice clips and rosin core solder.
Wrap each splice to insulate.
STEP 5.
Wrap with mylar and drain (uninsulated) wire.
1. DRAIN WIRE
STEP 6.
Tape over whole bundle to secure.
Twisted Leads Repair

STEP 1.
Locate damaged wire and remove insulation as re-
quired.
STEP 2.
Splice the two wires together using splice clips and
rosin core solder. See Figure 36.
1. SPLICE AND SOLDER
97
STEP 3.
Cover splice with tape to insulate from other wires.
STEP 4.
Twist and tape with electrical tape.
Micro-Pack
The Micro-Pack connector is shown in Figure 37.
This connector is normally used to connect the wire
harness to the ECM.
1. CABLE
2. TERMINAL
3. LOCKING TAB
4. TOOL KIT
Figure 37. Micro-Pack Connector
98
Metri-Pack crimped on the wire and the terminal pulled back

into the connector to seat it in place.
Some connectors use terminals called Metri-Pack Se-
ries 150. See Weather-Pack Terminal Repair. These Remove
may be used at the coolant sensor, as well as TBI
units. 1. Slide the seal back on the wire.
They are also called pull-to-seat terminals because to 2. Hold the wire and use it to push the terminal to
install a terminal on a wire, the wire is first inserted its forward position in the connector body. Hold
through the seal and connector. The terminal is then the terminal in this position. See Figure 38.
1. FEMALE TERMINAL 4. CONNECTOR BODY

2. LOCKING TAB 5. SEAL
3. TOOL KIT
Figure 38. Metri-Pack Terminal Removal
3. Find the lock tab for the terminal in the connec- 4. Use the removal tool to move the lock tab to re-
tor channel. Push a removal tool (pick) of the lease the terminal from its seat.
correct size into the connector channel. See Fig-
ure 39 and Figure 40. Push-to-Seat - Gently pull the wire to remove
the terminal from the back of the connector.
Pull-to-Seat - Gently push the wire to remove

the terminal through the front of the connector.
See Figure 41.
1. TOOL (PICK) 3. TERMINAL

2. LOCK TAB 4. CONNECTOR
BODY 1. TOOL (PICK) 3. TERMINAL
2. LOCK TAB 4. CONNECTOR
Figure 39. Metri-Pack Push-to-Seat Connector BODY
Figure 40. Metri-Pack Pull-to-Seat Connector
99
8. Push the seals into their position and install any

secondary locks.
1. TERMINAL NOTE: THE GREATER DISTANCE D, A FAULT CAN

2. LOCK TAB OCCUR IN THE CONNECTION.
3. TOOL KIT
4. CONNECTOR BODY 1. CONTACT TAB
5. SEAL
Figure 42. Metri-Pack Terminal Inspection
Figure 41. Metri-Pack Pull-to-Seat Terminal
Removal Weather-Pack
A Weather-Pack connector can be identified by a rub-
CAUTION ber seal at the rear of the connector. This connector,
Work carefully and do not use enough force to which is used in the engine compartment, protects
damage the terminal or the connector. against moisture and dirt which could create oxida-
tion and deposits on the terminals. This protection
5. Inspect the terminal and connector for damage.
is important because of the very low voltage and cur-
See Figure 42.
rent levels found in the electronic system.
NOTE: If reusing the terminal, reshape the locking
Repair of a Weather-Pack terminal is shown in
tab.
Weather-Pack Terminal Repair. Use the tool kit to
6. If the terminal will be used again, make sure the remove the pin and sleeve terminals.
lock tab is correctly bent so that the terminal will
If removal is attempted with an ordinary pick, there
be locked in the connector again.
is a good chance that the terminal will be bent or de-
7. Push the terminal into the connector channel. formed. Unlike standard blade-type terminals, these
Make sure that the lock tab correctly locks the terminals cannot be straightened once they are bent.
terminal in position.
100
Make certain that the connectors are properly seated Weather-Pack connections cannot be replaced with
and all of the sealing rings are in place when connect- standard connections. Instructions are provided
ing leads. The hinge-type flap provides a backup or with Weather-Pack connector and terminal pack-
secondary locking feature for the connector. They are ages.
used to improve the connector reliability by retaining
the terminals if the small terminal lock tabs are not
positioned properly.
Weather-Pack Terminal Repair
STEP 1.
Open secondary lock hinge on connector.
1. FEMALE CONNECTOR
2. MALE CONNECTOR
3. SECONDARY LOCK HINGE
STEP 2.
Remove terminal using tool.
1. TERMINAL
2. TOOL
STEP 3.
Cut wire immediately behind cable seal.
1. WIRE
2. SEAL
101
STEP 4.
Replace terminal.
a. Slip new seal onto wire.
b. Strip 5 mm (0.2 in.) of insulation from wire.
c. Crimp terminal over wire and seal.
STEP 5.
Push terminal and connector onto wire and engage locking tabs.
STEP 6.
Close secondary lock hinge.
1. SEAL
102
TECHNICAL PUBLICATIONS
900 SRM 1088 5/06 (11/04)(8/04)(6/04)(3/04)(2/04)(1/04)(12/03) Printed in U.S.A.

Electronic Controlled Lpg/Gasoline Fuel System: GM 3.0L and 4.3L Epa Compliant Engines

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ELECTRONIC

PART NO. 1559540 900 SRM 1088

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2006 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

H2.00-3.20XM (H40-65XM) [H177];

Special service tools shown in this service manual

AL - Adaptive Learn. CARB - California Air Resources Board.

Description and Operation of LPG Fuel System

Legend for Figure 1

Figure 1. Typical Fuel System Schematic

LPG FUEL TANK SERVICE LINE

Figure 2. Typical Propane Cylinder

Figure 3. In-Line Fuel Filter

AIR FUEL MIXER

The air valve mixer is an air/fuel metering device

The air fuel mixer is attached to the throttle con-

Figure 7. Three-Way Catalytic Muffler

Figure 8. LPG Electronic Control Module

Figure 9. LPG Closed Loop Control Schematic

The HEGO sensor is mounted in the exhaust sys-

Description and Operation of Gasoline Fuel System

Legend for Figure 11

Figure 11. Gasoline Throttle Body Injection System

Legend for Figure 12

Figure 12. Gasoline Multi-Point Fuel Injection System

Figure 14. Fuel Rail Assembly

Figure 13. Throttle Body Injector Unit THROTTLE CONTROL DEVICE

FUEL RAIL AND PRESSURE REGULATOR, Drive By Cable

Figure 15. Drive By Cable Throttle Body

Also mounted to the throttle control device is an in-

Figure 17. Gasoline Electronic Control Module

Figure 18. Gasoline Closed Loop Control Schematic

pulse to the injectors. The ECM continuously moni-

Figure 19. Heated Exhaust Gas Oxygen Sensor

LPG Fuel System Repair

Install 1. Relieve the propane fuel system pressure. Refer

1. Apply pipe thread sealant to the LPR inlet fit-

2. Install the LPL to the LPR. Tighten the LPL fin-

NOTE: * IS FOR 3.0L ONLY.

Figure 21. Low Pressure Regulator Assembly

Remove 6. Disconnect the supply and return coolant lines

Install 10. Disconnect the FTV supply line.

6. Connect the laptop computer and verify the en- Install

Legend for Figure 22

Figure 22. 3.0L Mixer and Throttle Body Assembly

Figure 23. 4.3L Mixer and Throttle Body Assembly

Legend for Figure 23

TEMPERATURE MANIFOLD ABSOLUTE Do not attempt to make any adjustments to the

15. Remove throttle body assembly. MIXER REPLACEMENT

Install 1. Disconnect the negative battery cable.